APRILIA 2Q000504 Service Station Manual Download

Page: 400 / 597

Installing connecting rods - pistons

The piston rings are different and must be fitted

with the "KDN5" markings (for the upper one)(A)

and "K-TOP and KDN5" markings (for the lower

one )(B) facing upward.

The five ring gaps (two piston rings, two oil scraper

rings, one oil scraper spring) are fitted displaced

90º to each other, starting from the exhaust-side

stud bolt opposite the chain and continuing clock-

wise.

The fitted pistons have two selections A and B.

Therefore they are coupled with the cylinder ac-

cording to the selection of the latter, which is

marked on the upper crankcase halves.

Pre-assemble the pistons on the workbench with

the connecting rod shank and the relative semi-

bushing.

The pre-assembly procedure is identical for all four

pistons and must be done as follows:

•

with the piston crown parallel to the

workbench and the arrow (1) posi-

tioned from the side opposite of the

operator, fit the connecting rod shank

with the bevelling (2), on the hole of the

rod head, on the right side.

Engine

Tuono V4 1100 Factory

ENG - 400

Summary of Contents for 2Q000504

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

Page 2: ...icle itself All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only While the basic features as described and illustrated in this manual remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication befo...

Page 3: ...ions and changes in repair procedures are communicated to all Aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on update...

Page 4: ......

Page 5: ... CHARACTERISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS BODYWORK BODYW ...

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

Page 7: ...ights low beam lights taillights front and rear and relevant warning lights Headlight adjustment according to regulations in force Rear brake light push button Turn indicators and their warning lights Instrument cluster Instrument cluster warning lights Horn Electric starter Engine stop via emergency stop switch and side stand Through the diagnostic tool check that the last mapping version is pres...

Page 8: ...ecessary charge the battery CHARGE LEVEL ACTION NUMBER OF BARS Ready for use 5 6 Charging recommended 3 4 Charging necessary 1 2 Fault 0 RECHARGE Always use a specific charger for lithium batteries to recharge the battery To avoid damage to the battery the charging voltage must NEVER be higher than 15 volts Do not charge the battery with a charger with automatic DESULPHATION MODE using a voltage h...

Page 9: ...tep on it Do not perform welds on the battery terminals Do not use the battery in combination with primary batteries such as dry batteries or batteries of different capacity type and brand Do not use the battery if it emits a strange odour emits heat changes colour or deforms or if it presents any anomaly Stop use immediately if the battery is in use or under charge THE BATTERY DOES NOT CONTAIN HA...

Page 10: ...ng the six cells This operation is extremely important in or der to have the best battery perform ance over time Recharge the battery following the specifications indicated on the battery see photo and using a suitable bat tery charger NOTE IN THE SHOWN EXAMPLE IT IS IMPORTANT TO USE A BATTERY CHARGER WITH 1 2 AMPERE CHARGING TIME 5 10 HOURS OR 5 AMPERE CHARGING TIME 1 HOUR Levels check Hydraulic ...

Page 11: ...ct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Check the frame and engine numbers Check included tools where applicable Licence plate fitting Locks checking Tyre pressure check Fitting of mirrors and possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY BURST CAUTION CHECK AND ADJUST TYRE PRESSURE ...

Page 12: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 13: ...LLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot parts The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down Coolant The ...

Page 14: ...ACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORTAN...

Page 15: ...e material Lubricate the parts when possible before reassembling them When tightening screws and nuts begin with the larger diameter or internal ones proceeding diagonally Tighten with subsequent steps before applying the prescribed torque Always replace the locknuts gaskets seal rings snap rings O Rings OR cotter pins and screws if they have damaged thread with new ones When disassembling the bea...

Page 16: ...SING OTHER PROBLEMS THAT WOULD COMPROMISE MA NOEUVRABILITY LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your riding speed during the running in period This ensures that compo...

Page 17: ...mber consists of numbers and letters as in the example shown below ZD4KZA00YSXXXXXX KEY ZD4 WMI World Manufacturer Identifier code KZ model A00 Europe UA0 USA Tuono V4 1100 B00 Europe UB0 USA Tuono V4 1100 Factory 0 digit free Y year of manufacture S production plant S Scorzè XXXXXX serial number 6 digits CHASSIS NUMBER The chassis number is stamped on the RH side of the headstock ENGINE NUMBER Th...

Page 18: ... adjustments with calibrated pads Lubrication system Wet sump with oil radiator Oil pump Dual trochoidal pump lubrication cooling Oil filter With external cartridge filter Cooling Liquid Cooling system 3 way thermostatic valve cooling radiator with electric fan and expansion tank Coolant pump Centrifugal bearingless aspirating pump with integrated ce ramic gasket Air filter Paper Transmission DRIV...

Page 19: ...ELECTRICAL SYSTEM Specification Desc Quantity Spark plugs NGK IR MR9DI 7 Electrode gap 0 6 0 7 mm 0 023 0 027 in Battery BS BATTERY BSLi 04 LITHIUM 12V 48Wh 280A Alternative solution YUASA YTZ10S 12V 8 6 Ah Coils Stick coil Recharging system Flywheel with rare earth magnets Alternator 360 W Main fuse 30A Secondary fuses 5A 4 7 5 A 3 15 A 20 A ABS fuses 10 A 25 A ASC fuse if supplied 7 5 A FUNCTION...

Page 20: ...an be electronically adjusted for hydraulic brake compression and extension and mechanically adjusted for spring pre loading Rear shock absorber Tuono V4 1100 Sachs With progressive linkage with APS system Shock absorber with piggy back that can be adjusted for spring pre loading hydraulic brake compression and extension Rear travel Tuono V4 1100 Factory Ohlins ASC 62 mm 2 44 in Rear travel Tuono ...

Page 21: ...SUPPLY Specification Desc Quantity Fuel Unleaded gasoline E10 95 R O N FUEL SUPPLY SYSTEM Specification Desc Quantity Throttle body diameter 48 mm 1 89 in Type Electronic injection with 2 injectors per cylinder 4 motorised throttle bodies Ride by wire with fixed height air intakes dif ferentiated per main bearing front rear 2 dynamic air intakes Selectable multimap Tightening Torques If the follow...

Page 22: ...T BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED BEFORE FITTING THE NEW SCREWS CLEAN THE THREADED HOLES CAREFULLY MAKING SURE THAT ALL TRACES OF THE OLD THREAD LOCK SEALANT HAVE BEEN ELIMINATED Chassis Front side FRONT WHEEL Pos Description Type Quantity Torque Notes 1 Front wheel axle nut M25x1 5 1 80 Nm 59 00 lb ft 2 Front brake disc fastening screws M8 6 6 30 Nm 22 13 lbf ft Loct 243...

Page 23: ...ening screws M10x1 25 2 2 50 Nm 36 88 lbf ft FRONT FORK OHLINS ASC TUONO V4 1100 FACTORY Pos Description Type Quantity Torque Notes 1 Calliper mounting bracket fixing screws M6 2 2 10 Nm 7 37 lbf ft 2 ABS sensor fixing screw M5 1 8 Nm 5 90 lbf ft Tuono V4 1100 Factory Characteristics CHAR 23 ...

Page 24: ...antity Torque Notes 1 Calliper mounting bracket fixing screws M6 4 10 Nm 7 37 lbf ft 2 ABS sensor fixing screw M5 1 8 Nm 5 90 lbf ft 3 Upper cap 2 20 Nm 14 75 lbf ft 4 Upper cap locking nut 2 20 Nm 14 75 lbf ft Characteristics Tuono V4 1100 Factory CHAR 24 ...

Page 25: ... bend the two opposing tabs into the notches on the lock ring 6 Headstock counter lock ring tight ening M35x1 1 Tighten by hand To lock the counter lock ring while bending the tabs in the notches it can be turned further by 35 or unscrewed by max 10 7 Upper yoke fixing cap 1 100 Nm 73 76 lb ft 8 Screw fastening spacer to the chas sis M8x25 1 20 Nm 14 75 lbf ft Loctite 243 9 Screw used to fasten th...

Page 26: ... 2 1 4 Nm 0 88 1 03 lbf ft 9 LH light switch int clamp M5 1 4 Nm 2 95 lbf ft 10 Screw for fastening the Ride By Wire control to the semi handlebar M4 1 2 2 Nm 1 62 lbf ft FRONT BRAKE MASTER CYLINDER Pos Description Type Quantity Torque Notes 1 Screw fastening front brake fluid res ervoir to bracket M6 1 7 Nm 5 16 lbf ft 2 Screw fastening brake fluid reservoir mounting bracket to handlebar M6 1 7 N...

Page 27: ...6 1 10 Nm 7 38 lbf ft FRONT ELECTRICAL SYSTEM Pos Description Type Quantity Torque Notes 1 Voltage regulator fastening screws M6 2 6 Nm 4 42 lbf ft 2 Horn fixing screw M8 1 15 Nm 11 06 lbf ft Starter relay cables fastening screws M5 2 4 Nm 2 95 lbf ft Tuono V4 1100 Factory Characteristics CHAR 27 ...

Page 28: ...scription Type Quantity Torque Notes 1 Top fairing fixing screws M4 4 0 5 Nm 0 37 lb ft DUCTS Pos Description Type Quantity Torque Notes 1 Duct fixing screws 4 4 Nm 2 95 lbf ft Characteristics Tuono V4 1100 Factory CHAR 28 ...

Page 29: ...FRONT MUDGUARD ENGINE FAIRING Pos Description Type Quantity Torque Notes 1 Front mudguard fixing screws M5 4 7 Nm 5 16 lbf ft Central part Tuono V4 1100 Factory Characteristics CHAR 29 ...

Page 30: ... for fastening the water by pass pipe tube gland M5 1 6 Nm 4 43 lbf ft 4 Screws for fastening the electric fans to the water radiator M4 6 0 5 Nm 0 37 lbf ft 5 Screw for fastening the expansion tank M6 1 5 Nm 3 69 lbf ft Loct 243 OIL RADIATOR Pos Description Type Quantity Torque Notes 1 Screw fastening oil radiator to mounting bracket M6x25 1 7 Nm 5 16 lbf ft 2 Hex head flange screws fastening bra...

Page 31: ...shing M18x1 5 1 12 Nm 8 85 lbf ft 4 RH upper rear regulator bushing M18x1 5 1 12 Nm 8 85 lbf ft 5 RH upper rear coupling M10 1 50 Nm 36 88 lbf ft 6 LH upper rear coupling M10 1 50 Nm 36 88 lbf ft 7 LH upper rear engine coupling fas tening screws M8 3 25 Nm 18 43 lbf ft 8 Saddle mounting fixing screws M10 4 50 Nm 36 88 lbf ft Tuono V4 1100 Factory Characteristics CHAR 31 ...

Page 32: ...e rod joint and gear lever 1 8 Nm 5 90 lbf ft Loct 6 Nut used to fasten the gearbox tie rod to the quick shift device 1 8 Nm 5 90 lbf ft 7 Gearbox lever fixing screws M6 2 8 Nm 5 90 lbf ft 8 Pin for fastening the gear change lev er to the footrest support M8 1 25 Nm 18 44 lbf ft Apply water repellent grease between the O rings and the Quick Shift uniball NOTE ONCE ASSEMBLE THE DISTANCE BETWEEN THE...

Page 33: ...bf ft 2 Screws used to fasten the passeng er s footrest to the saddle support M8 2 2 18 Nm 13 28 lbf ft 3 Rider s heel guard fastening screws M6 2 2 8 Nm 5 90 lbf ft 4 Passenger s heel guard fastening screws M6 2 2 8 Nm 5 90 lbf ft 5 Rider s footrest anti creep stud M6 2 8 Nm 5 90 lbf ft Tuono V4 1100 Factory Characteristics CHAR 33 ...

Page 34: ...ctite 243 4 Tank filler cap 1 17 23 Nm 12 54 16 96 lbf ft 5 Brake lever ferrule fastening screw M6 1 8 Nm 5 90 lbf ft SIDE STAND Pos Description Type Quantity Torque Notes 1 Screws for fastening the stand to the frame M10 2 45 Nm 33 19 lbf ft Loct 243 2 Rotary switch fixing screw M6 1 10 Nm 7 37 lbf ft Loct 243 3 Stand fastening pin 1 Nm lbf ft 4 Fastener nut of side stand 1 Nm lbf ft Characterist...

Page 35: ... Screws used to fasten the side fair ings to the spacers M5 2 1 5 Nm 1 11 lbf ft FUEL TANK Pos Description Type Quantity Torque Notes 1 Fastener screw of left hand side cov er mounting bracket M5 1 3 Nm 2 21 lbf ft Tuono V4 1100 Factory Characteristics CHAR 35 ...

Page 36: ... sensor to mounting bracket M6 2 6 Nm 4 42 lbf ft 7 Fastener screws of plastic mount for fuel pipe M5 1 2 5 Nm 1 84 lbf ft 8 Hex head flange screws for fastening fuel pump M5x16 6 4 Nm 2 95 lbf ft 9 Pre impregnated hex head screws used to fasten the fuel level probe flange M6 4 2 3 Nm 1 69 lbf ft SADDLE Pos Description Type Quantity Torque Notes 1 Rider saddle fastener screw M5 2 6 Nm 4 43 lbf ft ...

Page 37: ...lbf ft 2 Shear head screw to the left of the ignition lock M8x28 1 manual tighten until the head shears off 3 Right hand cylindrical head hex socket fastener screw of ignition switch block M8x35 1 25 Nm 18 43 lbf ft 4 Nut fastening saddle lock to tail fair ing M22x1 25 1 5 Nm 3 68 lbf ft Tuono V4 1100 Factory Characteristics CHAR 37 ...

Page 38: ...5 lbf ft 3 Screw used to secure the silencer to the RH footrest support M8 1 25 Nm 18 44 lbf ft 4 Exhaust valve motor support fixing screw M6 1 8 Nm 5 90 lbf ft 5 Lambda probe fastener M12x1 25 2 25 Nm 18 43 lbf ft 6 Silencer heat shield fixing screws M6 3 8 Nm 5 90 lbf ft 7 Exhaust valve opening closing lock nut M6 2 5 Nm 3 69 lbf ft Characteristics Tuono V4 1100 Factory CHAR 38 ...

Page 39: ...IT Pos Description Type Quantity Torque Notes 1 Oil tube screws M10x1 4 23 26 Nm 16 96 19 18 lbf ft 2 Control unit support screws M6 2 6 8 1 Nm 5 01 0 74 lbf ft Back side Tuono V4 1100 Factory Characteristics CHAR 39 ...

Page 40: ...d fastener screw M5 3 2 Nm 1 47 lbf ft 6 Rear stand bushing retaining screw M6 2 7 Nm 5 16 lbf ft 7 Chain tensioner shoe adjustment screws M8 2 Adjust the screw until the head is in contact with the tensioner shoe and then tighten the lock nut to the specified torque REAR BRAKE CALLIPER Pos Description Type Quantity Torque Notes 1 ABS sensor fixing screw M5x15 1 8 Nm 5 90 lbf ft 2 Screws fastening...

Page 41: ...ue Notes 1 Rear wheel axle nut M25x1 5 1 120 Nm 88 51 lbf ft 2 Nuts used to fasten the crown to the sprocket M10 5 50 Nm 36 88 lbf ft 3 Rear brake disc fastening screws M8 5 30 Nm 22 13 lbf ft Loct 243 Tuono V4 1100 Factory Characteristics CHAR 41 ...

Page 42: ...36 88 lbf ft 2 Dual connecting rod fixing screw M10 3 50 Nm 36 88 lbf ft 3 Screw fastening single connecting rod to chassis M10 1 50 Nm 36 88 lbf ft REAR LIGHTS Pos Description Type Quantity Torque Notes 1 Direction indicator fastening screws M6 2 2 5 Nm 1 84 lbf ft Characteristics Tuono V4 1100 Factory CHAR 42 ...

Page 43: ...REAR BODYWORK Pos Description Type Quantity Torque Notes 1 Passenger saddle support fixing screws M8 3 18 Nm 13 27 lbf ft Engine Tuono V4 1100 Factory Characteristics CHAR 43 ...

Page 44: ...n to torque unscrew and re tighten to torque 4 Engine timing inspection cap 1 20 Nm 14 75 lbf ft 5 Spacers for soundproof cover 5 6 Nm 4 43 lbf ft 6 Oil level dipstick 1 3 Nm 2 21 lbf ft 7 Oil load cap 1 5 Nm 3 69 lbf ft VALVES COVER Pos Description Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 38 lb ft 2 TE flanged coil fixing screw M6x12 4 8 Nm 5 90 lb ft Loct 243 3 Spark plugs...

Page 45: ... Type Quantity Torque Notes 1 Screws fastening water union onto crankcase M6x40 2 10 Nm 7 38 lb ft HEADS Pos Description Type Quantity Torque Notes 1 Exhaust stud bolts 8 10 Nm 7 38 lb ft Tuono V4 1100 Factory Characteristics CHAR 45 ...

Page 46: ... 13 40 57 lb ft Lubricate the head and under the head 6 Head tightening screw chain side M6x55 4 12 Nm 8 85 lb ft Lubricate the head and under the head TIMING SYSTEM Pos Description Type Quantity Torque Notes 1 Screw fastening the timing system gear on the intake shaft M8 4 30 Nm 22 13 lb ft Loct 243 2 Chain tensioner sliders fastening screws M8 2 20 Nm 14 75 lb ft Loct 243 3 Chain guide sliders f...

Page 47: ...01 2 Primary fixing ring nut 1 200 Nm 147 51 lbf ft Loct 243 3 Flywheel fastener screw M12x1 25 1 120 Nm 88 51 lbf ft 4 Stator SHC fixing screw M6x30 3 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 5 Fastener screws for pick up retainer plate 2 6 Nm 4 43 lbf ft Pre impregnated screw and in ab sence Loct 2045 Tuono V4 1100 Factory Characteristics CHAR 47 ...

Page 48: ...ixing fuel rail gearbox lubrication M6x12 2 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 8 TB TORX fixing screw of the con necting rods lubrication nozzles 4x12 4 5 Nm 3 69 lbf ft Pre impregnated screw in absence Loct 2045 9 TSPEI screw fixing bearing stop plates M6x16 2 10 Nm 7 38 lbf ft Loct 243 10 Stud bolt M6 1 Bring to 33mm from the surface Loct 648 11 SHC screw M6x40 1 1...

Page 49: ...ing bearing retainer plates M6x16 3 10 Nm 7 38 lbf ft Pre coated screw if not pre coated apply 3M SCOTCH GRIP 2353 to thread 3 Flanged hex head flange retaining screws M8x25 6 25 Nm 18 44 lbf ft Lubricate with oil 4 Special screw with index lever fas tening collar M6 1 10 Nm 7 38 lbf ft Loct 243 5 Hex head flange screw for fastening sprocket M10x35 1 50 Nm 36 88 lbf ft Loct 243 6 Screw used to sec...

Page 50: ...h M20x1 1 150 Nm 110 63 lbf ft Loct 243 2 Clutch springs SHC fixing screw M6x25 6 10 Nm 7 38 lbf ft IGNITION UNIT Pos Description Type Quantity Torque Notes 1 Hex headed nut cl 10 type 2 iso 8674 M10x1 1 50 Nm 36 88 lbf ft Loct 243 Characteristics Tuono V4 1100 Factory CHAR 50 ...

Page 51: ...and re tighten to torque 2 Cover fastening screws M6x40 3 12 Nm 8 85 lbf ft Tighten to torque unscrew and re tighten to torque 3 Blow by coupling SHC fastening screws M5x16 3 5 Nm 3 69 lbf ft 4 Spacers for soundproof cover 3 6 Nm 4 43 lbf ft 5 Soundproof cover fastening screws M6 3 6 Nm 4 43 lbf ft 6 Fastener screws for timing sensor re tainer plate 1 Nm lbf ft Stator SHC fixing screw M6x30 1 10 N...

Page 52: ...e unscrew and re tighten to torque 4 Oil pressure sensor 1 15 Nm 11 06 lbf ft 5 Flanged TE rose pipe fastening screw M6x16 1 10 Nm 7 38 lbf ft Pre impregnated screw in absence Loct 2045 6 SHC screw fixing pump to the casing M6x16 5 10 Nm 7 38 lbf ft 7 SHC screw fixing pump to the casing M6x50 1 10 Nm 7 38 lbf ft 8 SHC screw fixing oil pipe connection M6x20 1 10 Nm 7 38 lbf ft Characteristics Tuono...

Page 53: ...SECONDARY AIR SYSTEM Pos Description Type Quantity Torque Notes 1 Cylindrical head hex socket secon dary air solenoid screws M6x16 2 10 Nm 7 38 lbf ft Tuono V4 1100 Factory Characteristics CHAR 53 ...

Page 54: ...ATER PUMP Pos Description Type Quantity Torque Notes 1 Cylindrical head hex socket screws for fastening the pump to the crank case M6x25 2 10 Nm 7 38 lbf ft Characteristics Tuono V4 1100 Factory CHAR 54 ...

Page 55: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 56: ...e Description 020845Y Engine support 020846Y Containment tray plastic plugs 020847Y Flywheel extractor 020914Y Flywheel stop 020849Y Clutch retainer tool 020850Y Primary gear lock Special tools Tuono V4 1100 Factory S TOOLS 56 ...

Page 57: ...iming pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020981Y Lever for disarming the hydraulic tension er of the timing chain 020980Y Piston assembly ring 020857Y Crankshaft support U bolt Tuono V4 1100 Factory Special tools S TOOLS 57 ...

Page 58: ...P8140199 Tool storage panel 8140426 Hooks for panel 020860Y Motor support extension 020862Y Punch assembly cage with rollers gear box control rod 020863Y Punch assembly cage with rollers des modromic drum 020864Y Engine support plate Special tools Tuono V4 1100 Factory S TOOLS 58 ...

Page 59: ...ort for camshaft gear on head 020883Y Fitting removing timing chain tensioner tool 020709Y Engine support AP8140187 U bolt for motor support 020376Y Adaptor handle 020363Y 20mm oil seal guide Tuono V4 1100 Factory Special tools S TOOLS 59 ...

Page 60: ...Y 25 mm guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Bearing extractor AP8140179 Valve springs compressor 0277308 Guide bushing for gearbox secondary shaft Special tools Tuono V4 1100 Factory S TOOLS 60 ...

Page 61: ...fitting clutch bushing AP8140146 Weight AP8140189 Tool for mounting the oil seal for holes with diam 43 mm 1 69 in AP8140149 Guard for assembly operations AP8140190 Steering tightening tool 01761 04 Ohlins fork cap ring nut Tuono V4 1100 Factory Special tools S TOOLS 61 ...

Page 62: ...clamp 020889Y Wrench for locking pumping unit ring nut 020890Y Support rod of pumping unit stanchion AP8140181 Tool for checking fuel pressure 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles Special tools Tuono V4 1100 Factory S TOOLS 62 ...

Page 63: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 64: ... I I Steering bearings and steering play 5 I I I I I Wheel bearings Wheels 5 I I I I I Diagnosis by tool I I I I I Brake discs 5 Pads wear 2 I I I I I Air filter 5 I R I R Engine oil filter 5 R R R R R Raked I I General vehicle operation 5 I I I I I Valve clearance 6 A A Cooling system 5 I I I I Brake systems 5 I I I I I Light circuit I I I I I Safety switches stand stop clutch extra negative stro...

Page 65: ...owing occurs first 40 000 km 24 854 miles or 4 years SCHEDULED MAINTENANCE TABLE Km x 1 000 or months maximum 1 1 10 10 20 20 30 30 40 40 Rear shock absorber bearings linkage systems 5 I I Motorcycle set up 5 I I I I I Spark plug R R Drive chain 3 I L I L I L I L I L Clutch cable L L L L L Exhaust valve control cables 5 A A A A A Crown wheel sprocket 5 I I I I Steering bearings and steering play 5...

Page 66: ... SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES Key I CHECK AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE 1 Check at each engine start 2 Check and clean adjust or replace if necessary before every journey 3 Check and clean adjust or replace if necessary every 1 000 km 621 mi 4 Replace every 4 years 5 Every 5 000 Km 3 106 mi i...

Page 67: ...6 I I Labour time minutes 130 150 390 150 480 110 140 To carry out the correct verification Flexible coupling pin nuts tightening indicated in the scheduled maintenance table refer to the corresponding procedure in chapter Maintenance Verification Flex ible coupling NOTE AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORREC...

Page 68: ... 4656 ASTM D 4985 CUNA NC 956 16 DOT 4 brake fluid Synthetic brake fluid SAE J 1703 FMVSS 116 ISO 4925 CU NA NC 956 DOT4 ÖHLINS 5W Öhlins fork oil SAE 5W Hydraulic fluid HVI 32 Fork oil Application Sachs ISO L HV Spark plug To remove the spark plugs the fuel tank and the complete filter box must first be removed Then proceed as described FRONT SPARK PLUGS Cylinder 2 4 After releasing the front coi...

Page 69: ...ifting it as indica ted Release the connector from the sup port on the filter housing and discon nect it After having removed the fixing screw of the coil disconnect it from the spark plug and remove it While refitting make sure you pass the coil wiring harness behind the wiring harnesses on the filter housing Using a special spark plug wrench un screw and remove it Tuono V4 1100 Factory Maintenan...

Page 70: ...to facilitate the coil removal After having removed the fixing screw of the coil disconnect it from the spark plug and remove it While refitting place the wiring harness under the air pressure sensor pipes Using a special spark plug wrench un screw and remove it Check the efficiency and check the electrode gap If they are not within the parameters replace them Engine oil Maintenance Tuono V4 1100 ...

Page 71: ...ht with both wheels on the earth Ensure that you are on a flat surface Unscrew the engine oil level dipstick 1 Clean the engine oil level dipstick 1 and put it back in without screwing it in Remove it again and check the engine oil level The level is correct if it reaches the MAX level approximately Otherwise top off the engine oil CAUTION THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MARKING O...

Page 72: ...ary replace the drainage plug sealing washers Remove the oil filter Spread a thin layer of oil on the sealing ring of the new engine oil filter Insert and screw the new engine oil fil ter in the seat filling the filter to 1 3 of its capacity with engine oil before fit ting Screw and tighten the drainage plug Introduce 4 l 0 88 UK gal 1 06 US gal engine oil of the specified type Screw on the filler...

Page 73: ...o torcycle using a torque wrench check and if necessary tighten the nuts fixing the crown to the support to the prescri bed torque Engine oil filter Replace the engine oil filter each time you change the engine oil Drain the engine oil completely Unscrew and remove the engine oil fil ter from its seat NOTE NEVER REUSE AN OLD FILTER Spread a thin layer of oil on the sealing ring of the new engine o...

Page 74: ...ector from the control unit After having disconnected the VEHI CLE connector from the control unit release the wiring harness from the two cable glands on the filter housing From the support on the filter housing disconnect the cylinder 3 coil connec tor Remove the three screws fixing the ECU support to the filter housing Maintenance Tuono V4 1100 Factory MAIN 74 ...

Page 75: ...ed the fixing screw of the engine wiring harness support release it from the filter housing by lift ing it as indicated Remove the quick shift connector from its seat Remove the nine fixing screws of the filter housing cover Tuono V4 1100 Factory Maintenance MAIN 75 ...

Page 76: ...l tank to be able to reach the filter housing area and proceed as follows COVER REMOVAL Disconnect the ENGINE connector from the control unit After having disconnected the VEHI CLE connector from the control unit release the wiring harness from the two cable glands on the filter housing Maintenance Tuono V4 1100 Factory MAIN 76 ...

Page 77: ...ete with support After having removed the fixing screw of the engine wiring harness support release it from the filter housing by lift ing it as indicated Remove the quick shift connector from its seat Remove the nine fixing screws of the filter housing cover Tuono V4 1100 Factory Maintenance MAIN 77 ...

Page 78: ... from the cable gland on the fil ter housing cover Disconnect from the supports on the filter housing the coil connectors and the power supply connector from the main wiring harness to the engine wir ing harness Remove the filter housing cover Maintenance Tuono V4 1100 Factory MAIN 78 ...

Page 79: ...nnect the main wiring harness and the canister system valve from the cable gland on the filter housing base Operating on the left side of the vehi cle remove the screw that fastens the front bank oil pressure sensor to the base of the filter housing removing al so the gear sensor connector support bracket Tuono V4 1100 Factory Maintenance MAIN 79 ...

Page 80: ... intake ducts Partially lifting the filter housing base after having removed the pipe clamps disconnect the vapour recovery pipe of the blow by valve on the left and the vapour recovery pipe of the sas valve on the right Operating on the left side of the vehi cle remove the clamp that fastens the engine wiring harness to the filter hous ing base Maintenance Tuono V4 1100 Factory MAIN 80 ...

Page 81: ...Air filter housing installation To install the filter housing carry out the removal procedure in reverse order paying particular at tention to the following operations CLAMP PRE FITTING Place a suitably sized clamp on the en gine wiring harness next to the grey taping and secure it to the filter housing base Do not tighten the clamp to facilitate the connection of the front bank coil con Tuono V4 ...

Page 82: ...ront head cover and the spark plugs Remove the sound proofing cover from the clutch side Remove the clutch cover Turn the crankshaft in the normal di rection of rotation of the engine with a wrench applied to the primary gear fas tener nut until the valves are under spring tension Use a feeler gauge to check the clear ance between the cam of the shaft and the relative tappet for both front head sh...

Page 83: ...ar head shafts Characteristic Acceptable values with control clearance be tween cam and valve intake 0 10 0 15 mm 0 0039 0 0059 in ex haust 0 20 0 25 mm 0 0079 0 0098 in Front cylinder head valves Check the front cylinder head valve clearance val ues and adjust if necessary to attain the correct values following the procedure described below Remove both cylinder head covers the soundproofing cover...

Page 84: ...the engine rotation direction direction of travel Insert the pin from the flywheel side in to the hole in the crankshaft Specific tooling 020852Y Crankshaft timing pin Fit the pin for aligning the intake cam shaft with the hole in the bearing cap Specific tooling 020851Y Camshaft timing pin Loosen the second screw of the cam shaft drive sprocket Maintenance Tuono V4 1100 Factory MAIN 84 ...

Page 85: ... the specific camshaft gear sup port tool Fasten to the head with the two screws Specific tooling 020956Y Support for camshaft gear on head Remove the second screw of the cam shaft drive sprocket Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool s spacer Tuono V4 1100 Factory Maintenance MAIN 85 ...

Page 86: ...he ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Retrieve the buckets using a magnet Remove the calibrated pads with a magnet and replace with new calibra ted pads of the size necessary to attain the correct valve clearance value See the paragraph Calibrated pad thickness to determine the correct thickness CAUTION RE...

Page 87: ...t and fit and hand tighten the seven screws indicated Use new copper washers on the four screws near the spark plug holes Loosen the camshaft sprocket lock screw on the tool Slide the sprocket off the holder tool and onto the camshaft CAUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM SHAFT Apply Loctite 243 thread lock adhesive to the first screw of the ...

Page 88: ...kshaft in direction of engine rotation only as far as neces sary to reveal the second fastener hole for the sprocket Apply Loctite 243 thread lock adhesive to the thread of the second fastener screw of the camshaft sprocket this screw must be replaced with a new component at each reassembly and tighten the screw to the specified tor que Continue rotating the crankshaft in di rection of rotation of...

Page 89: ...move both cylinder head covers the soundproofing covers the alternator side cover and the clutch cover Move cylinder piston 1 left rear piston to the TDC Start rotating the crankshaft in the di rection of rotation of the engine with a wrench applied to the primary gear fas tener nut As soon as the first fastener screw of the camshaft gear is visible remove the screw Continue rotating the crankshaf...

Page 90: ... cam shaft drive sprocket Remove the pin from the camshaft drive sprocket Unscrew and remove the three screws 1 and remove the bearing cap 2 and the oil pipe 3 Remove the second screw of the cam shaft drive sprocket CAUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM SHAFT Maintenance Tuono V4 1100 Factory MAIN 90 ...

Page 91: ...the seven screws in progres sive steps in a criss cross pattern and remove Retrieve the copper washers from the screws near the spark plug holes Remove the bearing caps complete with O rings and alignment pins Remove the intake and exhaust cam shafts If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear ...

Page 92: ...thickness to determine the correct thickness CAUTION REMOVE THE TAPPET CAREFULLY AS THE PAD MAY FALL INTO THE ENGINE Refit the bucket tappets Refit the camshafts ensuring that they are aligned correctly If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Maintenance Tuono V4 110...

Page 93: ...TION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM SHAFT Remove the tool for holding the cam shaft drive sprocket gear on the head Apply Loctite 243 thread lock adhesive to the first screw of the camshaft sprocket and hand tighten the screw only Fit the bearing cap the oil pipe and the three fastener screws Tighten the ten fastener screws of the camshafts ti...

Page 94: ...aced with a new component at each reassembly and tighten the screw to the specified tor que Continue rotating the crankshaft in di rection of rotation of engine to bring it back to the previous position in which the holes in the camshaft and the bear ing cap were aligned insert the refer ence pin while checking with the crank shaft reference pin that the flywheel side hole and the hole on the cran...

Page 95: ...9 in 1 82 mm 0 0716 in 1 85 mm 0 0728 in 1 87 mm 0 0736 in 1 90 mm 0 0748 in 1 92 mm 0 0756 in 1 95 mm 0 0768 in 1 97 mm 0 0775 in 2 mm 0 0787 in 2 02 mm 0 0795 in 2 05 mm 0 0807 in 2 07 mm 0 0815 in 2 1 mm 0 0827 in 2 12 mm 0 0835 in 2 15 mm 0 0846 in 2 17 mm 0 0854 in 2 2 mm 0 0866 in Tuono V4 1100 Factory Maintenance MAIN 95 ...

Page 96: ... 0 1012 in 2 6 mm 0 1024 in 2 62 mm 0 1031 in 2 65 mm 0 1043 in 2 67 mm 0 1051 in 2 7 mm 0 1063 in 2 72 mm 0 1071 in 2 75 mm 0 1083 in 2 77 mm 0 1090 in 2 8 mm 0 1102 in 2 82 mm 0 1110 in 2 85 mm 0 1122 in 2 87 mm 0 1129 in 2 9 mm 0 1142 in 2 92 mm 0 1150 in 2 95 mm 0 1161 in 2 97 mm 0 1169 in 3 mm 0 1181 in 3 02 mm 0 1189 in 3 05 mm 0 1201 in 3 07 mm 0 1209 in 3 10 mm 0 1220 in 3 12 mm 0 1228 in ...

Page 97: ... expansion tank is between the FULL maximum and LOW minimum marks WARNING CARRY OUT THE CHECK AND TOP UP THE REFRIGER ANT LIQUID WITH THE ENGINE SWITCHED OFF AN COLD Top up To top up the cooling system it is necessary to re move the right side fairing Then proceed as de scribed Remove the expansion tank filler plug Top up the system by checking the lev el using the appropriate reference marks on t...

Page 98: ... RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESER VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE TO AVOID SPILLING FLUID WHILE TOPPING UP KEEP THE LEVEL OF THE FLUID IN THE RES ERVOIR PARALLEL WITH THE EDGE OF THE RESERVOIR ...

Page 99: ...HE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE LEVER IS TOO LONG OR IN CASE OF FLUID LOSS IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM HAVE THIS PROCEDURE PERFORMED BY AN Authorised Aprilia Dealer Rear braking system Unscrew and remove the upper nut 5 from the rear brake pump Top up the reservoir with the recom mended brake fluid to reach the correct level on the sight glass 6 CAUTION ONLY...

Page 100: ...nd Partially undo the screw 4 Turn the cam 5 searching for the best position for the pedal Tighten the screw 4 and check the cam is stable in position Clutch system Adjusting the lever Adjust the clutch when the engine stops or the ve hicle tends to move forward even when clutch lever is operated and the gear engaged or if the clutch slides resulting in acceleration delay con sidering the engine r...

Page 101: ...Make sure that the engine does not stop or that the vehicle does not tend to move or that the clutch does not slip during acceleration or while rid ing Headlight adjustment NOTE IN COMPLIANCE WITH LOCAL LEGISLATION SPECIFIC PROCEDURES MUST BE FOLLOWED WHEN ALIGNING THE LIGHTS To quickly check if the headlamp is aimed correct ly place the vehicle on a level surface 10 m 32 8 ft from a vertical wall...

Page 102: ...e used to adjust the vertical alignment of the low beam headlight beam NOTE CHECK THAT THE VERTICAL ALIGNMENT OF THE BEAM IS CORRECT HIGH BEAM HEADLIGHT Operating from underneath the head lamp unit turn the adjuster screw 3 TIGHTEN clockwise to lower the light beam LOOSEN anticlockwise to raise the beam This adjuster screw may be used to adjust the vertical alignment of the high beam headlight bea...

Page 103: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 104: ...Components arrangement Key 1 Side stand sensor 2 Fuel pump 3 Instrument cluster Electrical system Tuono V4 1100 Factory ELE SYS 104 ...

Page 105: ... sensor 17 Rear speed sensor 18 Headlamp 19 Rear turn indicators 20 Licence plate light 21 Taillight 22 Horn 23 Voltage regulator 24 Battery 25 Secondary fuses 26 Main fuse 27 11SM control unit 28 Rear brake switch 29 Stator with timing sensor 30 Coils 31 Starter motor 32 Oil pressure sensor 33 Inertia platform 34 Accelerator control 35 Quick Shift 36 a PRC commands 37 Modulator ABS control unit 3...

Page 106: ...ne the correct cable harness routing layout to ensure the reliability of the vehicle Materials used and corresponding quantities The electrical system consists of the following wiring harnesses and parts 1 x Main vehicle wiring harness 1 x Licence plate holder wiring harness 1 x Engine Battery Earth Cable Only for TUONO V4 1100 Factory OHLINS ASC 1 x Main vehicle wiring harness 1 x Ohlins fork wir...

Page 107: ...Check the ground fastening on the starter motor starter motor positive and relative hood Check the taillight connection Check the connection between the number plate holder wiring harness and the main wiring harness Check the fuel pump connection Check the regulator connection Check fastening of the chassis engine ground cable Check the flywheel regulator connection Check the Lambda connection fro...

Page 108: ...ONNECTORS HAVE BEEN LISTED AS THEY ARE MORE CRITICAL THAN OTH ERS AND THEIR DISCONNECTION MAY CAUSE VEHICLE BREAKDOWN OR MALFUNCTION NATURALLY IT IS ALSO NECESSARY THAT ALL OTHER CONNECTORS CONNECTED COR RECTLY TO ENSURE THAT THE VEHICLE FUNCTIONS CORRECTLY THE INSTRUCTIONS FOR ROUTING AND FASTENING THE WIRING HARNESS THROUGHOUT THE VEHICLE MUST BE FOLLOWED PRECISELY TO ENSURE THAT THE VEHICLE FUN...

Page 109: ...REA Using a rubber cable gland fasten the right side light switch wiring harness 1 with the wiring harness of the demand sensor 2 The wiring harness of the light switch must pass between the right side in strument panel support and the chas sis as indicated BOTH WIRING HARNESSES MUST PASS ABOVE THE FRICTION CABLE Tuono V4 1100 Factory Electrical system ELE SYS 109 ...

Page 110: ...g harness 4 Immobilizer signal wiring harness 5 Ignition switch wiring harness TABLE A4 ROUTING THE CABLES IN THE IN STRUMENT PANEL SUPPORT AREA Place the ASC ECU 1 if applicable as indicated Put all wiring harnesses together and fasten them using a rubber clamp 2 and the clip clamp 3 that was previ ously installed Electrical system Tuono V4 1100 Factory ELE SYS 110 ...

Page 111: ...g a clamp in the position corresponding to the blue taping TABLE A6 ROUTING THE CABLES IN THE IN STRUMENT PANEL SUPPORT AREA Connect the connector on the ASC ECU if applicable and lay the wiring harnesses as indicated fastening them with the clip clamp that was pre viously installed Tuono V4 1100 Factory Electrical system ELE SYS 111 ...

Page 112: ...ence taping with its GREY counterpart that has the same BLUE reference TABLE A8 ROUTING THE CABLES IN THE IN STRUMENT PANEL SUPPORT AREA To make space inside the instrument panel support place the connectors 1 in the indicated area on the right hand side support Electrical system Tuono V4 1100 Factory ELE SYS 112 ...

Page 113: ...nector to return without interferences All other connectors inside the instru ment support arch must be well con nected and placed inside it using all free spaces TABLE A10 ROUTING THE CABLES IN THE INSTRUMENT PANEL SUPPORT AREA Place the USB provision connector as indicated in the picture so as to allow easy access when the accessory will be fitted Tuono V4 1100 Factory Electrical system ELE SYS ...

Page 114: ... gently pull the instrument panel in the direction of the arrow so as to tension the cables If the connection is connection is correct the connector will stay in its place TABLE B FRONT ABS SPEED SENSOR PRE FITTING OHLINS After having placed the front ABS speed sensor on the fork leg secure the wiring harness using a cable gland 1 and a clamp 2 Electrical system Tuono V4 1100 Factory ELE SYS 114 ...

Page 115: ...ecured the sensor arrange its wiring harness 2 as indicated and secure it with two clamps 3 TABLE B1 FRONT ABS SPEED SENSOR Pass the front ABS speed sensor wir ing harness as shown and using a clamp secure it together with the main wiring harness on the radiator support Tuono V4 1100 Factory Electrical system ELE SYS 115 ...

Page 116: ...eed sensor wir ing as shown and secure it with two clamps to the main wiring harness TABLE B3 FRONT ABS SPEED SENSOR Use cable glands to secure the front ABS speed sensor wiring harness to the brake pipe Electrical system Tuono V4 1100 Factory ELE SYS 116 ...

Page 117: ...airing at the indicated point TABLE D ELECTRONIC FORKS IF PRESENT Pre install the wiring harness 1 of the electronic forks on the upper steering plate and after having secured it by means of special clamps 2 in the in dicated points tighten the screws 3 of the cover 4 Tuono V4 1100 Factory Electrical system ELE SYS 117 ...

Page 118: ...port TABLE D2 ELECTRONIC FORKS IF PRESENT The wiring harnesses that will be con nected to the stanchion cap must pass over the front of the steering plate as indicated After having checked the correct con nection place the rubber protection covers Electrical system Tuono V4 1100 Factory ELE SYS 118 ...

Page 119: ...ING DAMPER IF PRESENT Route the steering damper cable to ward the damper TABLE E1 ELECTRONIC STEERING DAMPER IF PRESENT Secure the wiring harness with a clamp at the indicated point Tuono V4 1100 Factory Electrical system ELE SYS 119 ...

Page 120: ...ess as shown and insert it into its cover TABLE F1 CLUTCH SWITCH PRE FITTING After having placed the switch on the clutch control and after having inserted the nut screw it in until the thread pro trusion is 4 mm Electrical system Tuono V4 1100 Factory ELE SYS 120 ...

Page 121: ...NESS Place the main wiring harness as indi cated TABLE A1 VEHICLE CABLE HARNESS Check that the wiring harness with the VEHICLE connector is facing up and secure the conduit to the chassis Tuono V4 1100 Factory Electrical system ELE SYS 121 ...

Page 122: ... sup port in central position Petrol pump relay with grey reference tape on the left support Then secure the main wiring harness next to the grey taping using cable glands TABLE A3 VEHICLE CABLE HARNESS Completely secure the main wiring har ness on the chassis using a clamp next to with the grey taping Electrical system Tuono V4 1100 Factory ELE SYS 122 ...

Page 123: ...indicated before proceeding with the installation of the engine on the ve hicle TABLE C VEHICLE ECU BRANCH Place the two cable glands as indica ted on the filter housing cover in order to secure the ECU branch Tuono V4 1100 Factory Electrical system ELE SYS 123 ...

Page 124: ...t as indicated TABLE D MAIN WIRING HARNESS CONNEC TION WITH THE ECU Connect the VEHICLE connector to the ECU and make sure that a CLICK is heard This noise confirms that the control unit is correctly con nected to the wiring harness Electrical system Tuono V4 1100 Factory ELE SYS 124 ...

Page 125: ...he connector is not secured try to close it until a CLICK is heard Repeat the test to check if the connec tors and closed and secured TABLE E COILS AND INJECTORS POWER SUPPLY CONNECTION Make sure that the engine wiring har ness connector is connected and that the wiring harness of the coil and of the power supply connector are placed un der the guide as indicated Tuono V4 1100 Factory Electrical s...

Page 126: ...the bulb correctly TABLE F1 ENGINE OIL PRESSURE SENSOR CONNECTION After bending the cap stem by 180 de grees place a clamp as indicated TABLE G GROUND LEADS The battery engine ground wiring har ness must not be visible in the area indicated by the red triangle symbol Electrical system Tuono V4 1100 Factory ELE SYS 126 ...

Page 127: ...ixing point on the en gine All wiring harnesses on the left side of the vehicle must pass inside the cable gland on the chassis at the indicated point TABLE G2 GROUND LEADS After having secured the screw grab the terminal with two fingers and try to gently move it If the terminal moves check the tightening of the screw Tuono V4 1100 Factory Electrical system ELE SYS 127 ...

Page 128: ...g system pipe using a clamp Place the main wiring harness inside the cable gland on the internal side of the chassis TABLE H1 WIRING HARNESS ON THE LOW ER CHASSIS SHOULDERS Operating on the internal left side place the wiring harnesses inside the cable gland on the internal part of the chassis Electrical system Tuono V4 1100 Factory ELE SYS 128 ...

Page 129: ...TARTER MOTOR IS NOT ROUTED OR SECURED COR RECTLY IT MAY CAUSE THE VEHI CLE CATCH FIRE CHECK THAT THE CABLE ON THE STARTER MO TOR IS PLACED AS INDICATED COVER THE STARTER MOTOR NUT AND THE SQUARE TERMINAL WITH DIELECTRIC WATER REPELLENT GREASE TABLE J RADIATOR FAN PRE FITTING The assembly is correct if the fan ca bles from the fan motor exits down ward as indicated Tuono V4 1100 Factory Electrical ...

Page 130: ...p wiring harnesses using two clamps Leave the circled area free TABLE K1 VOLTAGE REGULATOR Connect the left electric fan connector and lock it with a clamp as indicated Pass the wiring harnesses of the volt age regulator and of the pick up inside the pre installed cable gland on the canister Fasten the electric fan connector to the canister support Electrical system Tuono V4 1100 Factory ELE SYS 1...

Page 131: ...nesses with a clamp as indicated TABLE L EXHAUST VALVE MOTOR AREA WIRING HARNESSES The fan 1 and ride by wire 2 wiring harnesses must be routed between the chassis and the exhaust valve motor cables Tuono V4 1100 Factory Electrical system ELE SYS 131 ...

Page 132: ...em to the exhaust valve motor support TABLE L2 EXHAUST VALVE MOTOR AREA WIRING HARNESSES The electric fan wiring harness must be secured to the ride by wire wiring har ness with a clamp at the indicated point Check that the grey safety lock on the ride by wire connector is secured in the lowered position Electrical system Tuono V4 1100 Factory ELE SYS 132 ...

Page 133: ...y wire handle wiring harness 2 Radiator pipe 3 Main wiring harness IF THIS CABLE IS NOT ROUTED CORRECTLY IT MAY DAMAGE THE RIDE BY WIRE HANDLE TABLE M1 RIDE BY WIRE HANDLE CABLE ROUTING The wiring harness of the ride by wire handle must be secured with a clamp to the expansion tank breather pipe and to the fan wiring harness on the top and below it must pass through the in dicated cable gland Tuon...

Page 134: ...ogether with the lambda probe wiring and the quick shift to the crankcase cover fixing threaded pin TABLE O QUICK SHIFT PRE FITTING The quick shift must be placed as indi cated to facilitate the positioning of the wiring harness on the vehicle during installation Electrical system Tuono V4 1100 Factory ELE SYS 134 ...

Page 135: ...ving installed the quick shift place the wiring harness under the sprocket protective metal casing TABLE O2 QUICK SHIFT The quick shift wiring harness must be placed as indicated Tuono V4 1100 Factory Electrical system ELE SYS 135 ...

Page 136: ...ess at tached to the filter housing Connect the connector to its counter part and place it in the appropriate seat on the filter housing TABLE P REAR LAMBDA The cable gland must be placed as in the figure completely upward and the lambda sensor cable must be routed through it Electrical system Tuono V4 1100 Factory ELE SYS 136 ...

Page 137: ...DA After having correctly connected the rear lambda probe connector with its counterpart secure it using the special support to the sprocket metal protec tion cover Secure the wiring harness with a clamp at the indicated point Tuono V4 1100 Factory Electrical system ELE SYS 137 ...

Page 138: ... metal sup port Insert the wiring harness in the tow in dicated cable glands TABLE Q1 FRONT LAMBDA The wiring harness must pass behind the cooling system pipe TABLE R CONNECTIONS ON THE TANK After having inserted the fuel level probe place the wiring harness as in dicated passing it under the cover as indicated Electrical system Tuono V4 1100 Factory ELE SYS 138 ...

Page 139: ...or on the support on which the black connector of the fuel pump is lo cated as in the picture Back side TABLE X LICENCE PLACE HOLDER PRE FIT TING Place the three cable glands on the li cence plate holder in the indicated points Tuono V4 1100 Factory Electrical system ELE SYS 139 ...

Page 140: ... on the licence plate holder as indicated in the picture The arrow with the red tape must be connected with the wiring har ness branch that includes the grey tape TABLE X2 LICENCE PLACE HOLDER PRE FITTING Fit the clip on the wiring harness on the indicated area Electrical system Tuono V4 1100 Factory ELE SYS 140 ...

Page 141: ...it may result in fires and in correct vehicle operation 1 Ignition relay 2 Battery positive cable TABLE A2 IGNITION RELAY PRE ASSEMBLY After having correctly placed the cables tighten the two screws to the specified torque TABLE B PROCEDURE FOR THE CORRECT OPENING OF THE ABS CONTROL UNIT CON NECTOR GENTLY press with a screwdriver at the point marked by the arrow and pull up the lever with your fin...

Page 142: ...istance between the connector and the ABS con trol unit must be 7 5 mm TABLE C3 PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION If the initial position of the connector and the pull ing level is not as the one shown in TABLE C the connector will not hook correctly and the meas ured distance will be higher around 12 mm In this case repeat the operation as described in TABLE C1 C2 We reco...

Page 143: ...suit able cable clamp that must be inserted in the hole on the saddle column frame FIGURE D1 MAIN WIRING HARNESS Check that the connector has been in serted correctly as described in the preceding TABLES FIGURE D2 MAIN WIRING HARNESS The main wiring harness must be ar ranged as indicated Tuono V4 1100 Factory Electrical system ELE SYS 143 ...

Page 144: ...ed making sure not to fasten the wiring harness of the battery relay positive cable Secure the wiring harnesses on the two cable glands TABLE E1 ROUTING ON THE SADDLE COL UMN FOR THE STARTER RELAY After having correctly connected the starter relay 1 the taillight 2 and the turn indicators licence plate light 3 and after having placed them in their seats secure the main wiring harness in the two ca...

Page 145: ...ar ABS speed sensor connector is connected correctly and attached to its support TABLE F1 REAR SPEED SENSOR Pass the ABS rear speed sensor wiring harness through the cable gland inside the chassis on the right side TABLE F2 REAR SPEED SENSOR Insert the ABS rear speed sensor wir ing harness into the three cable glands on the swingarm Tuono V4 1100 Factory Electrical system ELE SYS 145 ...

Page 146: ...liper support TABLE F4 REAR SPEED SENSOR Place a cable gland that fastens the ABS rear speed sensor wiring harness to the brake pipe TABLE G REAR BRAKE SWITCH Check that the rear brake switch con nector is well connected to its counter part and then secure it to the main wiring harness with a clamp Electrical system Tuono V4 1100 Factory ELE SYS 146 ...

Page 147: ... the vehicle to the outside and must be inserted in the specific support as indicated TABLE I AMP CONNECTOR After having engaged the connector in the support pass the wiring harness inside between the saddle column frame and the under tail fairing TABLE J AMP CONTROL UNIT IF PRESENT After having secured the control unit connect the connector with its counter part Tuono V4 1100 Factory Electrical s...

Page 148: ...s as indica ted Secure the wiring harness with the ref erence C compression using a clamp together with the rear stop switch wiring harness and rear ABS speed sensor TABLE K2 ELECTRONIC SHOCK ABSORBER IF PRESENT Connect the wiring harness connector with the reference C compression and place it as shown TABLE L FUSES Place the three fuse boxes as indica ted Electrical system Tuono V4 1100 Factory E...

Page 149: ...General wiring diagram Legenda 1 Connettori multipli 2 Claxon 3 Devioluci sinistro 4 Devioluci sinistro 2 manettino Tuono V4 1100 Factory Electrical system ELE SYS 149 ...

Page 150: ...teriore 21 Relè comando ventola 22 Ventola 23 Sensor box 24 Fusibili secondari 1 FUSE 1 25 Fusibili sospensioni Ohlins FUSE 2 Ove previsto 26 Fusibili secondari 3 FUSE 3 27 Fusibili ABS FUSE 4 28 Generatore 29 Regolatore di tensione 30 Motorino di avviamento 31 Relè di avviamento Fusibile principale 30A 32 Batteria 33 Interruttore cavalletto laterale 34 relè iniezione principale 35 Relè pompa benz...

Page 151: ... map 2 63 Farfalla motorizzata 2 64 Sensore map 1 65 Farfalla motorizzata 1 66 Sensore temperatura aria 67 Sensore temperatura acqua 68 Pick UP sensore giri 69 Sensore pressione olio 70 Centralina 11 MP 71 Connettore cablaggio motore veicolo 72 Presa diagnostica OBD2 73 Centralina AMP ove previsto 74 Fanale anteriore completo LED 75 DRL Indicatore di direzione anteriore sinistro LED 76 LED anabbag...

Page 152: ...NG PROCEDURES ON THE VEHICLE CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V CONNECTOR CHECK PROCEDURE The procedure includes the following checks 1 Observation and check of the connector correct position on the component or on the coupling con nector making sure that the locking catch is re leased 2 Observation of the terminals on the connector no rust marks or dirt should be present and it is import...

Page 153: ...is correctly connected to the ground of the vehicle Tester set the tester selector to the continuity symbol and place one of the tester probes on the vehicle ground point or on the battery negative pole and the other probe on the cable under inspection Normally the tester will sound an audible signal to confirm continuity in the section of circuit tested Continuity may also be tested by setting th...

Page 154: ...CES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER INSTRUMENT PANEL ERRORS B0003 Immobilizer fault key code read but not recognised Error cause The read code is not stored in the instrument panel memory Troubleshooting Carry out key data storage procedure B0004 Immobilizer fault read key code not read key not present or transponder not working Error cause Key t...

Page 155: ...ternal controller fault Error cause There is a fault in the instrument panel Troubleshooting Replace the instrument panel System not programmed Storing new keys NOTE REGARDLESS OF THE LANGUAGE SET IN THE DASHBOARD FUNCTIONS THE KEY PRO GRAMMING PROCEDURE CAN ONLY BE VIEWED IN ENGLISH To carry out the one or more key pro gramming procedures up to a maxi mum of four you must connect the motorcycle t...

Page 156: ... TOOL WILL SHOW AN ERROR SAYING 1 KEY STORED The second key is stored and you will be asked to enter the third key if you have one The same operation will be repeated to store the fourth key To complete AND end the memorisa tion procedure set key to OFF You should then test the correct func tioning of all keys stored Dashboard In case of doubts in operation of the engine revs indication it is poss...

Page 157: ...d excepting the first an icon with the adjustable wrench is shown on the digital display To reset Service proceed as follows Connect the diagnostic tool Select the concerned model Enter in the INSTRUMENT PANEL section Select SELF DIAGNOSIS Select ACTIVATIONS Enable the command SERVICE RE SET Battery recharge circuit RECHARGING SYSTEM Remove the left side fairing Disconnect the three way connector ...

Page 158: ...tively the 3 connector pins stage 1 pin 1 2 stage 2 pin 1 3 stage 3 pin 2 3 Take the measurement The correct value is determined by the value measured for each stage in which from time to time the resistance of the tester wires is subtracted obtained by touching the two lugs Example Resistance of stage 1 read on the display 0 62 Ohm Resistance of the wires read on the display 0 47 Ohm Electrical s...

Page 159: ...or a correct detection of the alternator voltage a measurement must be carried out using alternatively the 3 engine side connector pins stage 1 pin 1 2 stage 2 pin 1 3 stage 3 pin 2 3 Take the measurements If there is a significant difference between one stage and another other than 15 V this means that the alternator is defective and must be replaced CAUTION WITH THE ENGINE HOT THE VALUES RECORDE...

Page 160: ...MINUTE FAILURE TO DO SO COULD CAUSE SERI OUS OVERHEATING DAMAGES TO THE MOTORCYCLE CIRCUITS COLD SHORT CIRCUIT CURRENT RPM 2000 4000 6000 8000 RMS DC current Arms average of the 3 stage currents 22 27 22 27 22 27 22 27 Voltage on battery poles with engine speed always between 3000 5000 RPM Start the engine after about one minute of operating bring the speed to 3000 5000 RPM then measure with a tes...

Page 161: ...ltage 5V 3 ground CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL ELECTRICAL ERRORS P0615 Starter relay short circuit to positive open circuit short circuit to negative Error cause Short circuit to positive excessive voltage ...

Page 162: ... malfunctions or when the engine does not start First check the auxiliary fuses and then the main fuses CAUTION DO NOT ATTEMPT TO REPAIR FAULTY FUSES NEVER USE A FUSE THAT IS DIFFERENT THAN WHAT IS SPECIFIED TO PREVENT DAMAGES TO THE ELECTRICAL SYSTEM OR SHORT CIRCUITS AND THE RISK OF FIRE CAUTION A FUSE THAT BLOWS FREQUENTLY MAY INDICATE A SHORT CIRCUIT OR OVERLOAD To check To avoid an accidental...

Page 163: ... for the instrument panel positive key on power for the right hand handlebar control set main start relay coil positive key on power for inertial sensor platform D 7 5A fuse ECU permanent positive lead E 5A fuse Positive key on power for AMP positive key on power for OBD positive key on power for USB positive key on power for the timer fitting F 5A fuse Positive key on power for headlamp load G 7 ...

Page 164: ...he supports and remove the protec tion cover to gain access to the main fuse O On the main fuse holder there is a spare fuse P LOCATION OF MAIN FUSE Specification Desc Quantity O 30A fuse Battery charging all vehicle utilities P spare fuse 30 A The main fuse is located on the rear part of the motorcycle under the tail fairing passenger saddle CAUTION REMOVING THE 30A FUSE WILL RESET THE DIGITAL CL...

Page 165: ...ectrical circuit diagram ASC Control Unit Location on the vehicle at the front connected to the instrument cluster mount connector on 34 PIN connector control unit 24 of which are active Pin out See CONNECTORS paragraph DIAGNOSTIC TOOL INFO screen page example values with key ON Hardware version indicates the hardware version BOOT version Software version Map identification DIAGNOSTIC TOOL ACTIVAT...

Page 166: ...CU PMP1 D08708 Communication interrupted with engine ECU ECU1 D08600 Invalid X axis acceleration sensor signal D08601 Invalid Y axis acceleration sensor signal D08602 Invalid Z axis acceleration sensor signal D08603 Invalid WX angular value sensor signal D08604 Invalid WY angular value sensor signal D08605 Invalid WZ angular value sensor signal D08606 Invalid front wheel speed sensor signal D08607...

Page 167: ...s Function It manages the Ride by wire system the injection ignition the system safety checks and the self diag nostic function Level in electrical circuit diagram Each level in which the main component involves the control unit Location on the vehicle above the filter box connector on control unit 80 PIN ENGINE connector 77 of which functional 66 PIN VE HICLE connector 53 of which functional Pin ...

Page 168: ...ttle valve potentiometer 2 voltage Rear throttle pot1 degrees Rear throttle Potentiometer 1 degrees Front throttle pot1 degrees Front throttle Potentiometer 1 degrees Rear int press 1 and 3 rear cylinders intake pressure 1 and 3 Front int press 2 and 4 front cylinders intake pressure 2 and 4 Rear int est press 1 and 3 rear cylinders intake estimated pressure 1 and 3 Front int est press 2 and 4 fro...

Page 169: ...ack km counter resettable from instrument Equiv track km total equivalent track km total counter Ign switch ass errors count ignition switch assembly errors counter km equiv reset count counter of the reset performed on partial km equivalents Gear sensor voltage Front lambda 2 adap corr front bank lambda 2 adaptive correction STATES Rear lambda 1 check rear bank lambda 1 check Front lambda 2 check...

Page 170: ...ruise ON OFF button indicates the status of the button relating to cruise control on the handlebar Cruise control SET Cruise control SET Rear coil 1 rear bank coil 1 Front coil 2 front bank coil 2 Rear coil 3 rear bank coil 3 Front coil 4 front bank coil Fuel pump Rev counter Rear lambda 1 heat rear bank lambda probe 1 heater Rear cyl 1 low inj rear bank cylinder 1 lower injector Front cyl 2 low i...

Page 171: ...warning light on fixed NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT DOWN P0605 ROM Error Electrical diagnostic Circuit not functioning Error cause Replace the injection control unit The instrument cluster indicates the presence of this error with the MI warning light on fixed NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT DOWN P060B A D converter Electrical diagnost...

Page 172: ...if not ok replace the relay if ok perform the check procedure for the relay connector the engine vehicle wiring harness connector and the ENGINE connec tor for the Marelli control unit if not ok restore if ok check the continuity of the wiring harness blue pink cable DIAGNOSTIC TOOL LOGIC ERRORS P160C Level 2 safety reset Error cause Due to the fact that the level 2 safety system comparison betwee...

Page 173: ...erformance Ride Control operating error Electrical diagnostic Incorrect a PRC scheduling Incorrect CheckSum of the software on Flash Control unit voltage too low for a PRC controls Error cause Due to the fact that the safety system detected a serious fault the control unit has disabled the a PRC system The instrument cluster indicates the presence of this error with the MI warning light on fixed T...

Page 174: ... BE SELECTED HANDLE SELF LEARNING AND CHECK THE TWO AUTOMATIC SELF LEARNING OF THE FRONT THROTTLE VALVES AND AUTOMATIC SELF LEARNING OF THE REAR THROTTLE VALVES STATES ARE CARRIED OUT ASC CONTROL UNIT Diagnosis Function It manages the ASC system the system safety checks and the self diagnosis function Level in electrical circuit diagram ASC Control Unit Location on the vehicle on the front part in...

Page 175: ...CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL LOGIC ERRORS P0560 Battery voltage too high too low Error cause If too high too high a voltage has been detected at PIN 42 If too low too low a voltage has been detected at PIN 42 The instrume...

Page 176: ...if not OK restore If OK check that cable resistance between the alternator cable and the control unit is a few tenths of Ohm if not OK repair the wiring harness if OK check that the electric generator is operating correctly Restore if not OK NOTE THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATION OF THE TRACTION CON TROL AND THE CRUISE CONTROL Speed sensor FRONT VEHICLE ABS SENSOR Function Gene...

Page 177: ... the ABS control unit Check the integrity and continuity of the wiring harnesses between PIN 3 of the ABS control unit and PIN 1 of the sensor white cable between PIN 12 of the ABS control unit and PIN 2 of the sensor white brown cable Short circuit to negative Disconnect the sensor connector Check the ground insulation of the two PINs If there is no insulation restore the wiring harness or replac...

Page 178: ... Check that the tyre is the correct size If all these checks are positive replace the sensor P2162 Wheel speed plausibility Error cause ABS system malfunction Troubleshooting Connect to the ABS control unit diagnosis REAR VEHICLE SPEED SENSOR Function Generates a signal used by the ABS control unit to determine the speed value of the wheel Operation Operating principle Magneto resistive sensor gen...

Page 179: ...tive or short circuit to positive Error cause Open circuit circuit interruption detected Short circuit to negative null voltage detected on PIN 14 of the ABS control unit Short circuit to positive excessive voltage detected on PIN 14 of the ABS control unit Troubleshooting Open circuit Check the connectors on the component and on the ABS control unit Check the integrity and continuity of the wirin...

Page 180: ...the tone wheel is correct Check that the tone wheel and the sensor are correctly positioned Check that the tyre is the correct size If all these checks are positive replace the sensor P2162 Wheel speed plausibility Error cause ABS system malfunction Troubleshooting Connect to the ABS control unit diagnosis Engine rpm sensor Function indicates the position and speed of the crankshaft at the Marelli...

Page 181: ...Y ARE OK CHECK THE SENSOR CONFORMS TO THE ELECTRICAL SPEC IFICATIONS IF NECESSARY REPLACE THE SENSOR IF IT IS OK CHECK THE CONTINUITY ON THE TWO CABLES VERIFYING THAT THEY ISOLATED FROM THE POWER SUPPLY AND EARTH CARRY OUT THE TESTS ON THE CONNECTOR OF THE SENSOR TOWARDS THE SEN SOR IF IT IS NOT OK REPAIR THE WIRING REPLACE THE SENSOR IF IT IS OK CARRY OUT THE TEST ON PINS 20 TO 35 OF THE MARELLI ...

Page 182: ...xt to the thermal valve Electrical specifications Pin out 1 A track power supply orange white cable 2 Sensors 1 ground green black cable 3 A track signal yellow cable 4 B track power supply orange black cable 5 Sensors 2 ground pink black cable 6 B track signal light blue cable DIAGNOSTIC TOOL ELECTRICAL ERRORS P0225 Track A handle position sensor Electrical diagnosis short circuit to positive ope...

Page 183: ...PIN 13 of the ENGINE con nector If open circuit short circuit to negative voltage equal to zero was detected at PIN 13 of the ENGINE connector This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light Troubleshooting short circuit to positive check the value indicated by the parameter handle position sensor track B disconnect the connec...

Page 184: ... the handle sensor connector and control unit connector if not OK restore If OK check that cable resistance between the handle sensor cable and the control unit is a few tenths of Ohm otherwise restore the wiring harness if ok replace the complete handle command Intake pressure sensor Function The pressure sensors one per bank are funda mental for calculation of generated torque for cal culation o...

Page 185: ... Rear Cylinder estimated Intake Pressure 1 and 3 Example value with key ON 1004 mbar Example value with engine on 735 mbar NOTE pressure estimated by the control unit according to the throttle position CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM...

Page 186: ... air pressure sensor P1105 short circuit to positive open circuit short circuit to negative signal not plausible Error cause Short circuit to positive excessive voltage has been detected on PIN 49 If open circuit short circuit to negative voltage equal to zero detected at PIN 49 Troubleshooting Short circuit to positive check on the diagnostic tool if the parameter of the rear cylinders air Pressu...

Page 187: ...al not plausible Error cause An average value of the intake pressure is estimated based on the engine operating data rpm throttle valve if the read value differs with a certain percentage then this error is activated The most frequent cases can be abnormal resistance in the sensor circuit for example rusted terminals or sensor with poor performance Troubleshooting Check the filter box large connec...

Page 188: ...between the estimated pressure and the measured pressure has been detected for example the pipe between sensor and throttle body is fully detached clogged or squashed Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean there is a very e...

Page 189: ...essure the measured pressure is below the estimated one for example smeared throttle body Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Engine temperature sensor Function It is used to indicate to the control unit the engine tempe...

Page 190: ...ers to an open circuit Engine temperature at start up Example value with key ON 40 C Example value with engine on 25 C The value of the engine start up temperature is saved At key ON the value 40 C is read CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SY...

Page 191: ...not supply the ground connection and therefore should be replaced If short circuit to negative check the correct resistance of the sensor if resistance is null replace the sensor if resistance is correct it means that the Yellow Brown cable has ground connection restore the cable harness DIAGNOSTIC TOOL LOGIC ERRORS P0116 Engine temperature sensor Signal not plausible Error cause An excessive temp...

Page 192: ...Pin out 1 0 5 V signal 2 Ground DIAGNOSTIC TOOL PARAMETERS Air temperature Example value with key ON 26 C 78 8 F This is one of the values set by the ECU in the event of recovery mode Air temperature before Recovery Example value with key ON 40 C 40 0 F Value determined from the signal read without tak ing into consideration the recovery mode the il lustrative value refers to an open circuit CAUTI...

Page 193: ...1 check the sensor connector and the Marelli control unit connector If not OK restore the cable harness If OK check for continuity between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2 restore the cable harness if there is no continuity If there is it means that the control unit does not supply the ground connection and therefore should be replaced If short circuit to negative ch...

Page 194: ...cuit at 5 V or higher the lambda probe parameter is not equal to the value read by the control unit but a recovery value is displayed Lambda correction Example value with key ON 0 Example value with engine on 10 10 In closed loop the value must be close to 1 00 values not within the 15 15 interval indi cate a fault In an open circuit the lambda probe signal is too low Therefore the control unit ta...

Page 195: ...tion of the relay with the colour of the cables is energised and the heating circuit is closed to ground 5 times pin 3 of the Lambda probe connector Electrical continuity is required in the wiring for the relay to activate cor rectly no errors are generated in case of no activation DIAGNOSTIC TOOL ELECTRICAL ERRORS P0150 Front bank lambda probe Electrical diagnosis Short circuit to positive Error ...

Page 196: ...entification with the cable colours if there are also errors regarding the coils lower and upper injectors and secondary air check the relay and its energy and power line if there is voltage at PIN 4 check ground insulation of the Black Violet cable PIN 3 if NOT OK restore the wiring harness if OK check the continuity of the Black Violet cable between PIN 3 of the sensor connector and ENGINE PIN 4...

Page 197: ...ed in the supply system poor pin sealing or in the probe Check the wiring harness if NOT OK restore if OK replace the lambda probe If no switching from low the fault may be generated in the supply system dirty injector low fuel supply system pressure or in the probe Check the wiring harness if NOT OK restore if OK replace the lambda probe For the non polarised type of probes this error may be caus...

Page 198: ...ircuit at 5 V or higher the lambda probe parameter is not equal to the value read by the control unit but a recovery value is displayed Lambda correction Example value with key ON 0 Example value with engine on 10 10 In closed loop the value must be close to 1 00 values not within the 15 15 interval indi cate a fault In an open circuit the lambda probe signal is too low Therefore the control unit ...

Page 199: ...ntification of the relay with the colour of the cables is energised and the heating circuit is closed to ground 5 times pin 3 of the Lambda probe connector Electrical continuity is required in the wiring for the relay to activate cor rectly no errors are generated in case of no activation DIAGNOSTIC TOOL ELECTRICAL ERRORS P0130 Front bank lambda probe Electrical diagnosis Short circuit to positive...

Page 200: ... OK restore the wiring harness if OK check the continuity of the Green cable between PIN 3 of the sensor connector and ENGINE PIN 32 and restore the wiring harness If open circuit short circuit to negative check the continuity from the probe connector PIN 3 and 4 to the probe if NOT OK replace the probe if ok perform the check procedure for the sensor connector and for the Marelli control unit con...

Page 201: ...n adjusted number of dead points PMS or TDC If no switching from low is shown when the ratio control is in closed loop and when the secondary air valve is not operating The error is validated if during the ratio control stage the switching from HIGH RATIO to LOW RATIO is missing for a certain adjusted number of upper dead points PMS or TDC The instrument panel indicates this error by lighting up i...

Page 202: ... engine revs the upper injectors in the field of high engine revs Operation Operating principle Injector coil is energised for the petrol passage to open Level in electrical circuit diagram Coils and injectors Position on the vehicle on the throttle body connector on injectors Electrical specifications 14 8 Ω 5 at ambient temp Pin out supply ground DIAGNOSTIC TOOL PARAMETERS Electrical system Tuon...

Page 203: ...ectrical circuit diagram placed under saddle right side CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation Electrical continuity is required in the wiring for...

Page 204: ...tive disconnect the injector connector set the key to ON and check if there is a ground connection on the orange red cable if the connection is present restore the cable harness If there is no connection replace the injector If open circuit check the component correct electrical characteristic if it is not the correct one replace the component if it is correct check the connector on the component ...

Page 205: ...tore the filter box cable harness If there is no voltage replace the sensor If short circuit to negative disconnect the injector connector set the key to ON and check if there is a ground connection on the white purple cable if the connection is present restore the cable harness If there is no connection replace the injector If open circuit check the component correct electrical characteristic if ...

Page 206: ... the injectors supply duct Low fuel tells to the instrument panel about low fuel Operation Operating principle Low fuel it is a resistance that if correctly supplied varies its electrical resistance if it is damped or not by petrol Level in electrical circuit diagram Injection load relay Location on the vehicle on the tank connector on right rear frame 4 ways black Electrical characteristics PIN 1...

Page 207: ...rcuit short circuit to negative Error cause Short circuit to positive excessive voltage has been detected at PIN 73 of the VEHICLE connector If open circuit short circuit to negative a voltage equal to zero was detected at PIN 73 of the ENGINE connector Troubleshooting Short circuit to positive check the relay electrical specifications are correct by disconnecting it from the cable harness If not ...

Page 208: ...ector with red strip on the engine wiring harness coil 4 with short cable to the right of the front part of the filter housing Electrical specifications 0 7 0 9 Ω at ambient temperature Pin out 1 Power supply Vbatt 2 Secondary circuit ground 3 Activation from the control unit DIAGNOSTIC TOOL PARAMETERS Example value with key ON Actual start up ad vance Example value with engine on Indicates the ad...

Page 209: ...o the battery positive CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the Brown Green cable of the coil is closed to ground for 2 ms per each second Dis connect the 4 way connector of the fuel pump to be able to hear the relay and injector activation Electrical continuity is required in the wiring for the relay to activate correctly no er...

Page 210: ...equal to zero was detected at PIN 27 of the ENGINE connector Troubleshooting Short circuit to positive disconnect the coil connector turn the key to ON activate the coil with the diagnostic tool and check the voltage at PIN 27 of the connector if there is voltage restore the wiring harness if the voltage is 0 replace the coil If open circuit short circuit to negative check the electrical character...

Page 211: ... Troubleshooting Short circuit to positive disconnect the coil connector turn the key to ON activate the coil with the diagnostic tool and check the voltage at PIN 1 of the connector if there is voltage restore the wiring harness if the voltage is 0 replace the coil If open circuit short circuit to negative check the electrical characteristics of the coil if not ok replace the coil if ok perform t...

Page 212: ...nk 1 3 and of the front bank 2 4 working on the throttle position an acceptable value should be between 0 5 and 0 5 Front throttle Potentiometer 1 degrees Example value with key ON 7 8 Example value with engine on 1 4 With key set to ON the throttle is kept in position by the springs around 5 7 After the engine starts up at idle the throttle is kept close to the mechanical minimum above or equal t...

Page 213: ...in position by the springs around 5 7 After the engine starts up at idle the throttle is kept close to the mechanical minimum above or equal to 0 5 When the gear is not engaged at approx 6000 rpm throttles open very little because the requested torque is too low around 5 7 Rear throttle Potentiometer 2 degrees Example value with key ON 8 2 Example value with engine on 1 6 With key set to ON the th...

Page 214: ...EPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES Front throttle automatic self learning Ice Interrupted Performed Limp home Throttle valve stopper closed Spring check Limp home acquisition Initialization Indicates if the self learning performed by the control unit was performed not performed this is funda menta...

Page 215: ...inals if not ok restore the wiring harness if ok check the ground insulation of the circuit from the throttle valve sensor connector or control unit connector if ground insulated check that the power supply 5 V is present at PIN 2 of the throttle body con nector and that ground is present at PIN 6 if present correctly replace the throttle body Rear bank throttle valve position potentiometer sensor...

Page 216: ...supply 5 V is present at PIN 2 of the throttle body con nector and that ground is present at PIN 6 if present correctly replace the throttle body Front throttle valve position potentiometer sensor CF2 P2125 short circuit to positive open circuit short circuit to negative Error cause Short circuit to positive excessive voltage has been detected on PIN 21 If open circuit short circuit to negative vo...

Page 217: ...d check that the resistance from the throttle control unit connector between PIN 29 and 41 is within 1 and 2 5 Ohm if not ok replace the throttle body if ok check that the throttle body is not mechanically blocked if blocked remove the cause or replace the body if not blocked replace the control unit Front throttle valve control circuit P1119 short circuit to positive short circuit to negative ope...

Page 218: ... resistance be tween the throttle body connector PIN 1 and the control unit PIN48 is a few tenths of an Ohm Otherwise restore the wiring harness if ok replace the complete throttle body Rear throttle valve potentiometer CF2 P2121 Signal not plausible Error cause Signal outside the specified value determined based on the values of the intake pressure Troubleshooting Check the parameter of the Poten...

Page 219: ... body Front throttle valve potentiometer CF2 P2126 Signal not plausible Error cause Signal outside the specified value determined based on the values of the intake pressure Troubleshooting Check the parameter of the Potentiometer 2 rear throttle voltage to get which signal the control unit receives and to compare it to the Potentiometer 2 front throttle voltage Check the throttle body connector an...

Page 220: ...ch key ON Troubleshooting Check the cleanliness of the throttle body and the intake duct If ok replace the throttle body Rear throttle valve minimum mechanical position self learning P1402 Test failed Error cause Position of the throttle valve stopper outside of the specified range at each key ON Troubleshooting Check the cleanliness of the throttle body and the intake duct If ok replace the throt...

Page 221: ...at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check the cleanliness of the throttle body and the intake duct If ok replace the throttle body Front throttle valve mechanical re closing springs self learning P1411 Test failed Error cause Throttle valve return time in the position maintained by the springs outside of the specif...

Page 222: ... perform the self learning test at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Remove the presence of errors that prevent throttle self learning Front throttle valve position error EPOS P0639 error Misalignment between control and activation Error cause The throttle valve mechanical control could be damaged Troubleshooting Re...

Page 223: ...OSTIC TOOL ADJUSTABLE PARAMETERS Throttle self learning NOTE AT EVERY KEY ON THE CONTROL UNIT PERFORMS A TEST ON THE THROTTLE VALVES TO CHECK THEIR MOBILITY ASSESSING THE NECESSARY FORCE TO MOVE THEM AN THE POTENTIAL PRESENCE OF OBSTACLES AT EVERY 150 KEY ON THE SYSTEM PERFORMS A STOPPER LEARNING FOR EACH THROTTLE BODY IF START UP IS ATTEMPTED DURING THIS PROCEDURE THAT REQUIRES APPROXIMATELY 3 SE...

Page 224: ...CTRICAL SYSTEM CHAPTER Dashboard Oil sensor FAULT error B0001 Error cause An oil sensor fault is signalled when with engine off it is detected that the sensor circuit is open The test is performed only once when the key is set to ON There is an error when the general warning light turns on Troubleshooting Check the sensor connector and the instrument panel connector PIN 13 if they are not OK resto...

Page 225: ...le Position on the vehicle under the chain pinion behind the pinion cover connector behind the filter housing 4 way transparent connector Electrical specifications VEHICLE connector PIN 64 neutral indication closed circuit continuity gear engaged open circuit infinite resistance Gear circuit voltage 1st gear 1 6 V 2nd gear 0 83 V 3rd gear 4 6 V 4th gear 3 9 V 5th gear 3 1 V 6th gear 2 4 V Pin out ...

Page 226: ...d check if the cable is energised if energised restore the wiring harness if not energised replace the sensor there is an interruption or a short circuit to positive of the Pink cable on the segment that goes from the sensor connector to the sensor or inside the sensor If short circuit to negative disconnect the sensor connector and with key ON check the voltage of the Grey Black cable if it is ze...

Page 227: ...ntrol unit connector paying attention to PIN 56 if not ok restore the wiring harness if ok disconnect the two ends from the sensor and with key ON check if there is continuity to ground at PIN 2 if there is no continuity restore cable harness if there is replace the sensor Indication on the diagnostic tool always Engaged disconnect the two ends from the sensor and check if with the clutch released...

Page 228: ... is active only with the lever released the problem is generated by the released clutch contact of the which is interrupted or by the engaged clutch contact which is in short circuit to ground If the error is active only with the lever engaged the problem is generated by the engaged clutch contact of the which is interrupted or by the released clutch contact which is in short circuit to ground If ...

Page 229: ...sis up down Troubleshooting Indication on the diagnostic tool always down perform the connector check procedure if not ok restore if ok disconnect the two ends from the sensor and check the PIN 1 continuity to ground if there is no continuity restore cable harness if there is replace the sensor Indication on the diagnostic tool always up disconnect the two ends from the sensor and check if with th...

Page 230: ...ay on off DIAGNOSTIC TOOL ACTIVATIONS Fan Energy is applied for 10 seconds to the fan relay 36 in the electrical circuit di agram position in the steering head stock recess to the right however CHECK the identification of the relay with the colour of the cables Electrical continuity is required in the wiring for the relay to activate correctly no errors are generated if the relay fails to acti vat...

Page 231: ...he cable harness If not OK replace the relay if OK restore the cable harness Brown cable If open circuit check the relay electrical characteristics are correct by disconnecting it from the cable harness if it is not OK replace the relay if it is OK check relay connector engine vehicle cable harness connector and VEHICLE connector of the Marelli control unit if not OK restore if OK check continuity...

Page 232: ...t cluster indicates the presence of this error with the MI warning light on fixed Troubleshooting Short circuit to positive disconnect the component set the key to ON start the vehicle and check if the error symptom is still shorted to positive it means that short circuit is between black white cable and a cable in voltage therefore restore cable harness if the error symp tom is short circuit to g...

Page 233: ...rown colour 3 Ground Green Pink colour 4 5V signal Engine stop Pink Yellow colour CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES RUN STOP switch Run Stop NOTES Indication on the diagnostic tool always STOP disconnec...

Page 234: ...he control unit connector is in short circuit to positive restore the wiring harness Butterfly valve in exhaust Function Used to reduce the noise at the exhaust The ex haust valve is controlled as follows Engine off fully closed 0 With engine on the exhaust valve as sumes different aperture values de pending on engine speed and load and on the gear selected Above 6000 rpm the valve is permanently ...

Page 235: ...n valve CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATES Exhaust valve Not determined searching activation at key ON in operation stopped due to detected faults zero searching NOTES If there is no problem the following ...

Page 236: ...ed range Check the correct voltage of the two cables of the valve If excessive duration check if the valve cables are energised if the valve cables are not powered connect correctly to power feed if voltage is correct check the mechanical oper ation of the exhaust valve to ensure that it rotates without impediment or sticking if not ok restore the normal valve rotation if ok check the electrical c...

Page 237: ...the instrument panel if there is no ground with key ON check if there is ground continuity at the connector PIN 2 if there is ground disconnect the instrument panel connector as well and if there is still ground restore the Black Red cable and if there is not replace the instrument panel if there is no ground check if PIN 3 or PIN 2 on the motor have ground continuity if they do replace the motor ...

Page 238: ...ter does not correspond to the one set by the control unit This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light Troubleshooting Perform a mechanical check of the valve check its normal rotation with the cables discon nected from the motor manually operate the cables and notice the movement regularity checking the complete stroke of...

Page 239: ...anical the valve could stay stuck in the closed position In the event of a CAN line malfunction the valve returns to the open position In the event of a check removal or replacement of one or more system cables valve motor a cali bration procedure is required CAUTION BEFORE CARRYING OUT THIS OPERATION CHECK THAT THE BATTERY VOLTAGE IS HIGHER THAN 12 5 V CAUTION WORK ON THE MOTOR OF THE EXHAUST THR...

Page 240: ...attery voltage is NOT below 12V Check that the cylinders are in their seat and are NOT obstructed If the cylinders are obstructed put them in their seats straight Check that the valve spring on the si lencer is in its seat Electrical system Tuono V4 1100 Factory ELE SYS 240 ...

Page 241: ...JUSTMENT SCREWS UP AGAINST THE SUPPORT PLATE WELDED TO THE SI LENCER Connect the PADS and carry out the valve zero actuator in the corresponding valve fully open position CAUTION CHECK THAT THE PULLEY HAS THE END STOP RESTING AGAINST THE END STOP OF THE SILENCER Tuono V4 1100 Factory Electrical system ELE SYS 241 ...

Page 242: ... opening cable adjuster screw up to the value corresponding to the value Y see values in the table CAUTION TURN THE ADJUSTER SCREW FULLY ANTI CLOCKWISE DIRECTION FOR TENSIONING THE ADJUSTER SCREW KEEPING THE COUNTER NUT STILL DO NOT TURN CLOCKWISE FOR ANY CORRECTIONS SINCE THE AD JUSTMENT IS DISTORTED DUE TO THE PLAY IF IT GOES BEYOND THE REQUIRED VALUE FULLY TIGHTEN THE ADJUSTER SCREW AND REPEAT ...

Page 243: ...for as sisted gear shift Operation Operating principle Two normally open switches that are closed to ground by operating the gearshift lever either in UP or DOWN gear Electrical circuit diagram Level in electrical circuit diagram Electronic gearbox Position on vehicle On the gearbox lever gear Connector position Under the fuel tank on the left side close to the rear big end Electrical specificatio...

Page 244: ...ition if NOT OK replace the sensor Check if between PIN 2 and PIN 3 there is a 500 Ohm resistance by bringing the lever in DOWN position if NOT OK replace the sensor Check if between PIN 2 and PIN 3 there is a 1000 Ohm resistance with the lever released if NOT OK replace the sensor With disconnected sensor voltage check Check if between PIN 3 and PIN 2 there is a 3 3 V voltage by bringing the leve...

Page 245: ...1906 error a PRC setting buttons Function To signal to the control unit the request for modi fication of the a PRC system settings Operation Operating principle Either control or is made up of a deviator with both outputs electrically connected to the in strument panel at the same time the instrument panel sends the requested command to the Marelli ECU via CAN line Electrical circuit diagram Level...

Page 246: ...ither of the two PINs a voltage over approx 1 V and at the same time a voltage below 1 V at the other PIN if this does not occur the instrument panel outputs the information to the control unit that shows this error Indication on diagnostic tool Invalid data due to short circuit error CASE 1 if this status is displayed with control not activated only it means that a voltage below 1V instead of bat...

Page 247: ...continuity on the red cable if it is not OK restore if it is OK check with control activated that there is not continuity of the button from the button connector between brown cable and red cable and then replace the control NOTES The control unit can not detect faults due to failed cable continuity P0570 command plausibility Electrical diagnosis Open contacts Closed contacts Error cause With open...

Page 248: ... if it is OK check continuity of the button from the button connector between black cable and green cable if it is not OK change the control if it is OK check with key to ON that the black cable is not grounded and then change the in strument panel CASE 2 if this status is displayed only with control activated it means that circuit from PIN 19 to PIN 34 of the instrument panel is interrupted check...

Page 249: ...cement of the control unit is recommended With signal not valid the sensor has generated a signal out of range that is still sent to the injection control unit together with the relevant error NOTE The instrument panel does not indicate the presence of this error even in the ATT status NOTE THIS ERROR DISABLES THE TRACTION CONTROL P1903 Yaw sensor plausibility Functional diagnosis Faulty sensor Si...

Page 250: ...nal diagnosis Timeout error Error cause If this error is displayed it means that the wheel stand control software detected an abnormal behaviour of the motorcycle Troubleshooting With faulty sensor the component inside the control unit is damaged and replacement of the control unit is recommended With signal not valid the sensor has generated a signal out of range that is still sent to the injecti...

Page 251: ...pin out key PIN 1 Cylinder 4 coil control output PIN 2 Cylinder 3 coil control output PIN 3 Output for front throttle valve engine command PIN 4 Sensor ground 2 Tuono V4 1100 Factory Electrical system ELE SYS 251 ...

Page 252: ...sure sensor input PIN 25 5 V reference voltage output A C tracks rear throttle valves and pressure sensor map PIN 26 5 V reference voltage output B D tracks front throttle valves PIN 27 Cylinder 2 coil command output PIN 28 Cylinder 1 coil command output PIN 29 Output for rear throttle valve engine command PIN 30 PIN 31 Recovery logic stop light relay command output PIN 32 Lambda 1 heater command ...

Page 253: ... Rear throttle valve potentiometer 1 signal input PIN 49 Front cylinders intake pressure sensor input PIN 50 Rear throttle valve potentiometer 2 signal input PIN 51 5 V reference voltage output A C tracks rear throttle valves and pressure sensor map PIN 52 Control unit direct power supply Vehicle pinout key PIN 53 Cylinder 1 upper injector command output Tuono V4 1100 Factory Electrical system ELE...

Page 254: ... PIN 66 L CAN line high speed PIN 67 Cylinder 2 upper injector command output PIN 68 Cylinder 4 upper injector command output PIN 69 Start up relay command output PIN 70 Side stand input PIN 71 PIN 72 Gear sensor input PIN 73 Injection relay command output PIN 74 Cylinder 3 upper injector command output PIN 75 PIN 76 Clutch sensor input PIN 77 PIN 78 Engine stop input PIN 79 PIN 80 H CAN line high...

Page 255: ...attery PIN B1 Injection power supply PIN B2 CAN line high PIN B3 CAN line low PIN B4 Key PIN B5 Electric fan relay control PIN B6 PIN B7 PIN B8 Power ground 1 PIN C1 Injection power supply PIN C2 K serial line for diagnostic PIN C3 Clutch engaged PIN C4 Start engine button PIN C5 Start up Tuono V4 1100 Factory Electrical system ELE SYS 255 ...

Page 256: ...ery positive PIN 2 PIN 3 PIN 4 Rear rebound 1A PIN 5 Front compression 1B PIN 6 Front rebound 1B PIN 7 PIN 8 PIN 9 PIN 10 Ground PIN 11 Steering dumping 1A PIN 12 Steering dumping 2B PIN 13 Rear rebound 1B PIN 14 Front compression 1A PIN 15 Front rebound 1A PIN 16 Electrical system Tuono V4 1100 Factory ELE SYS 256 ...

Page 257: ... rebound 2B PIN 24 PIN 25 CAN L line PIN 26 Rear compression 2B PIN 27 Rear compression 2A PIN 28 Rear compression 1B PIN 29 Rear compression 1A PIN 30 Rear rebound 2A PIN 31 Front compression 2B PIN 32 Front rebound 2A PIN 33 PIN 34 H CAN line Dashboard Instrument panel pinout key Tuono V4 1100 Factory Electrical system ELE SYS 257 ...

Page 258: ...4 High beam lights IN PIN 15 Normally closed TC switch PIN 16 Key positive PIN 17 Battery positive PIN 18 PIN 19 Normally open TC switch PIN 20 Normally closed DC switch PIN 21 PIN 22 Normally open TC switch PIN 23 Rear stop switch PIN 24 Ground PIN 25 Ground PIN 26 PIN 27 RH front arrow PIN 28 RH rear arrow PIN 29 LH front arrow PIN 30 LH rear arrow PIN 31 Fuel reserve PIN 32 L CAN line high spee...

Page 259: ...PIN 5 K serial line for diagnosis PIN 6 PIN 7 PIN 8 PIN 9 Battery positive for valves PIN 10 Pump engine ground PIN 11 L CAN line high speed PIN 12 Front speed sensor positive PIN 13 Rear speed sensor positive PIN 14 Rear speed sensor input PIN 15 PIN 16 PIN 17 PIN 18 Battery positive for pump engine Tuono V4 1100 Factory Electrical system ELE SYS 259 ...

Page 260: ...es travel at a bit rate of approximately 500 kbps de pending on the sent data package the information may arrive at the nodes in a time carrying from 4 ms to 100 ms CAN PROTOCOL CONT NETWORK AREA The communication protocol is CSMA CD Carrier Sense Multiple Access w Collision Detection In order to transmit every nod must first check that the BUS the connection among all devices is free before attem...

Page 261: ...s indicated by lighting up in a fixed manner the MI warning light Troubleshooting Carry out the Marelli control unit and the engine vehicle wiring harness connectors check procedure if not OK restore if OK check the ground insulation of the two CAN lines from PIN 66 and PIN 80 of the VEHICLE connector if not ok restore the wiring harness if ok check the continuity of the CAN lines from the VEHICLE...

Page 262: ...tore the cable harness if OK replace the instrument panel NOTE THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATION OF THE TRACTION CON TROL AND THE CRUISE CONTROL U1125 Frame counter Sensor Box CAN line diagnosis Electrical diagnosis Intermittent signal or communication error Error cause Probable bad contact in the CAN line This error is not indicated even in the ATT status Troubleshooting Perfo...

Page 263: ... OK perform the check procedure for PIN 3 and PIN 4 of the LH light switch connector if NOT OK restore and if OK check the general operation of the Marelli control unit and of the LH light switch in case of anomalies replace the part concerned NOTE THIS ERROR DISABLES THE CRUISE CONTROL DIAGNOSTIC TOOL LOGIC ERRORS U0121 ABSENT NODE ABS control unit Functional diagnosis Missing signal signal not p...

Page 264: ...OK with key OFF disconnect a the ABS control unit connector b the connector of the inertial platform Sensor box and check the continuity between PIN 3 of the inertial platform Sensor box and PIN 2 of the ABS control unit if NOT OK replace the vehicle wiring harness if OK check the continuity between PIN 2 of the inertial platform Sensor box and PIN 11 of the ABS control unit if NOT OK replace the ...

Page 265: ...ion error of the value of the rear wheel radius from the non volatile memory EEPROM to the volatile memory RAM at key ON In this case the default value is used This error is indicated by lighting up in a fixed manner the MI warning light NOTE THIS ERROR DISABLES THE TRACTION CONTROL P0564 Cruise control button Brake switch Electrical diagnosis brake sensors errors connect to the instrument panel d...

Page 266: ...oblem persists replace the LH light switch NOTE THIS ERROR DISABLES THE CRUISE CONTROL Presa USB The connector for connecting the USB port is sit uated inside the instrument cluster support and can be accessed from the left side of the vehicle Remove the front bodywork to access the connec tor Aprilia V4 MP Tecnology Sincronizzazione To use the system V4 MP the synchronisation that differs dependi...

Page 267: ...When the PMP ECU has been recognized it appears in the MY DE VICES list as PMP Click on PMP and wait for the smartphone to con nect When connected the PMP shows Connected Now the PMP is connected to the phone and in the V4 MP App you should note the motorcy cle data transmission After the first connection the system connects automatically to the instrument panel key ON ANDROID OPERATING SYSTEM Tuo...

Page 268: ...ueTooth active green button Wait for the smartphone to rec ognize the PMP ECU until you see PMP in Available devices list When the PMP is found click on the PMP line and make sure the smart phone is connected Once connected the PMP is added to the Paired devi ces list and in the menu PMP appears the message Paired Now the PMP is connected to the phone and in the V4 MP App you should note the motor...

Page 269: ...SITION BEFORE THE APP IS LAUNCHED CAUTION AFTER THE KEY IS OFF IT WILL BE NECESSARY TO WAIT FOR ABOUT 20 SECONDS TO EN SURE THAT THE WIRELESS CONNECTION IS CLOSED IN CASE OF CONNECTION FAILURE JUST EXIT THE APPLICATION USING THE APPROPRIATE BUTTON CLOSE IT FROM THE BACKGROUND MENU AND MANUALLY RESTART IT IF THE PREVIOUS DEVICE IS NOT IN THE AREA AFTER 20 SECONDS THE SYSTEM WILL BE AVAILABLE TO CON...

Page 270: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 271: ...ight of the vehicle to the semi handlebars and to a hoist Place the rear stand Removing the engine from the vehicle To proceed with the removal of the engine from the vehicle proceed as described Unscrew and remove the filler plug of the coolant radiator Use a container with a suitable capaci ty and operating from the left side of the vehicle remove the discharge screw of the cooling system Use a ...

Page 272: ...de electric fan and remove the safety clamp applied on the connector Remove the clamp that fastens the generator s alternator s wiring har nesses the oil pressure bulb the front bank lambda probe and the left side electric fan Temporarily move away the canister by blocking it using circlips to facilitate the subsequent operations Engine from vehicle Tuono V4 1100 Factory ENG VE 272 ...

Page 273: ...onnect it Release the connector of the demand sensor from the exhaust valve motor support and disconnect it Detach the expansion tank water drain pipe from the pipe guide connected to the mounting bracket of the radiators and remove the pipe retainer clip se curing the drain pipe to the cable of the demand sensor Tuono V4 1100 Factory Engine from vehicle ENG VE 273 ...

Page 274: ...nsion tank Remove the metal clamp and discon nect the oil pipe from the sump Remove the two fixing screws of the radiators support bracket Disconnect the connector of the front cylinder bank lambda probe and de tach it from the relative mount Engine from vehicle Tuono V4 1100 Factory ENG VE 274 ...

Page 275: ...o the thermostat valve Remove the metal clamp and discon nect the oil pipe from the coupling Move the metal clip along the pipe and disconnect the cooling system pipe from the radiator Remove the cable tie indicated and free the wiring harnesses from the ra diator mount Tuono V4 1100 Factory Engine from vehicle ENG VE 275 ...

Page 276: ... on the left side and remove both radiators by extracting them at the same time from the right side Loosen the metal clamp that fastens the front manifolds to the central ex haust manifold Unscrew the four fastener screws of the front cylinder bank headers and re move the headers Engine from vehicle Tuono V4 1100 Factory ENG VE 276 ...

Page 277: ...eads fixing screw and release the wiring harnesses Move the wiring harness to the outside and fasten them using a circlip Remove the internal cable gland on the left side of the vehicle to facilitate the engine removal Tuono V4 1100 Factory Engine from vehicle ENG VE 277 ...

Page 278: ... and removed the fixing nut of the start er motor power cable release the wir ing harness Loosen the clutch cable tensioning by using the adjuster nuts and disconnect it from the transmission lever and from the cover Remove the fastener screw of the gearbox lever and extract it from the primary shaft Engine from vehicle Tuono V4 1100 Factory ENG VE 278 ...

Page 279: ...isconnect the rear bank lambda probe connector and release it from its support Detach the springs and remove the centre exhaust manifold easing it out from underneath Remove the rubber cable ties and ex tract the tank s breather pipe Tuono V4 1100 Factory Engine from vehicle ENG VE 279 ...

Page 280: ...s and after hav ing removed the quick shift connector extract its wiring harness and the wir ing harness of the side stand s switch Unscrew the two fixing screws and re move the rider s footboard support from the left side Loosen the final drive chain tension to facilitate the sprocket removal Remove the fixing screw and retrieve the spring washer the T bushing and extract the sprocket from the se...

Page 281: ... Unscrew the nuts fastening the rear headers and remove the headers eas ing out towards the rear Unscrew the two side stand fixing screws and remove it Remove the screw that fastens the ABS modulator support to the chassis and the screw that fastens the metal plate to the support Tuono V4 1100 Factory Engine from vehicle ENG VE 281 ...

Page 282: ... modulator with the sup port extract the metal plate at the rear Disconnect the wiring harnesses from the cable gland inside the chassis on the right front side and after having moved them to the outside fasten them using a circlip together with the exhaust valve motor to facilitate the engine removal Engine from vehicle Tuono V4 1100 Factory ENG VE 282 ...

Page 283: ...o the chassis and re trieve the internal plate Completely unscrew the adjuster screw Unscrew the nut of the lower pin and extract it from the left side of the vehi cle Operating from the right side of the ve hicle completely unscrew the adjuster screw Operating from both sides remove the four screws that fasten the engine to the chassis and make sure to retrieve the spacer on the right side of the...

Page 284: ...n the left front internal side and release the ground lead that goes to the battery Complete the removal operation by lowering the engine and simultaneously lifting the front side of the vehicle to facilitate the process Installing the engine to the vehicle Before aligning the engine retainers prepare the right and left inserts on the engine with the precautions described below CAUTION THE REAR RI...

Page 285: ...nesses on the right side using a new clamp Insert the four front fixing screws together with the washers and the relative supports for mounting the side fairings making sure to insert the special spacers only for the right side and the lower pin inserting it from the left side together with the washer to align the engine Tighten to the specified torque only the two front screws on the left side Tu...

Page 286: ...ed the upper rear screw together with the washers tighten al screws to the speci fied torque Remove the engine support and insert the rear bank manifolds equipped with new gaskets Insert the locking nuts and screw them partially to facilitate the subsequent op erations for the assembly of the ex haust system Engine from vehicle Tuono V4 1100 Factory ENG VE 286 ...

Page 287: ...e gland Connect the springs that hold the rear manifolds joined with the central mani fold Place the engine spacer on the left side of the vehicle and secure it by tighten ing the four screws to the specified torque Place the stand with the support and secure it with two screws with washers Tuono V4 1100 Factory Engine from vehicle ENG VE 287 ...

Page 288: ...i fied torque Refit the wiring harness of the quick shift and of the side stand switch con necting the connectors with their coun terparts Secure the wiring harnesses with the cable tie Insert the chain guide slider together with the chain guide and fasten it with the three screws Refit the clamp that fastens the rear bank lambda probe wiring harness to the quick shift wiring harness and to the si...

Page 289: ... using the rubber cable tie to gether with the quick shift wiring har ness the side stand switch wiring harness and the rear bank lambda probe wiring harness Fit the sprocket cover and secure it us ing the three screws Insert the gearbox lever on the primary shaft and tighten the stop screw to the specified torque Tuono V4 1100 Factory Engine from vehicle ENG VE 289 ...

Page 290: ...rnal cable gland on the chassis Insert the main wiring harness branch in the right side cable gland and place the discharge valve support in its seat Place the starter motor power cable insert the washer and the nut and tight en them to the specified torque Refit the rubber protection cover Engine from vehicle Tuono V4 1100 Factory ENG VE 290 ...

Page 291: ...t the front left internal cable gland on the chassis and refit the wiring har nesses Connect the engine oil pressure bulb connector and refit the clamp that fas tens the wiring harness to it Connect the ground leads and tighten the fixing screw to the specified torque Tuono V4 1100 Factory Engine from vehicle ENG VE 291 ...

Page 292: ... system Connect the front bank lambda probe connector and engage it in its support Insert the radiators from the right side and engage the water radiator in the support on the left side CAUTION BEFORE FITTING THE RADIATORS MAKE SURE THEY ARE COMPLETELY EMPTY Operating from both sides insert and tighten the two screws used to fasten the radiator to the support Engine from vehicle Tuono V4 1100 Fact...

Page 293: ... right side and secure it using the specific metal clamp Connect the oil pipe to the fitting and secure it using a new metal clamp Connect the cooling system pipe to the pump the cross member that goes to the thermostatic valve and secure both of them using the metal clamps Tuono V4 1100 Factory Engine from vehicle ENG VE 293 ...

Page 294: ... the expansion tank breather pipe using a new clamp Connect the breather pipe to the de mand sensor wiring harness using a cable gland and then place the pipe on the cable gland connected to the radi ator support bracket Engage the connector of the demand sensor on the exhaust valve motor support Engine from vehicle Tuono V4 1100 Factory ENG VE 294 ...

Page 295: ... secure the generator alternator wiring harnesses the oil pressure bulb the front bank lambda probe and the left electric fan using a new clamp Insert the wiring harnesses in the cable gland connected on the rear side of the canister connect the left electric fan connector and secure it with a new clamp Connect the connector of the left side electric fan on the canister support Tuono V4 1100 Facto...

Page 296: ... on the sump and secure it using a new metal clamp Insert the oil discharge plug fitted with a new sealing gasket and tighten it to the specified torque Insert the coolant discharge screw fit ted with a new seal gasket and tighten it to the specified torque Engine from vehicle Tuono V4 1100 Factory ENG VE 296 ...

Page 297: ...port at the back into the rubber ring Insert the screw that fastens the ABS modulator support to the chassis and the screw that fastens the metal plate to the support and then tighten them to the specified torque Tighten the clamp that fastens the pipes of the ABS system Tuono V4 1100 Factory Engine from vehicle ENG VE 297 ...

Page 298: ...cedure Insert 2 7 l 0 59 Uk gal and check the level in the expansion tank Insert 4 1 l 0 90 Uk gal of engine oil and check the level with the dipstick Connect the fuel tank the voltage regulator and battery Subsequently with the vehicle on the central stand start the engine and wait for the activation of the cooling fans Stop the engine check the oil and coolant levels again and top up if necessar...

Page 299: ...INDEX OF TOPICS ENGINE ENG ...

Page 300: ... rear left cylinder 2 front left cylinder 3 rear right cylinder 4 front right cylinder Combustion sequence 1 3 2 4 Combustion angle cyl 1 0 cyl 2 180 cyl 3 425 cyl 4 605 Engine Tuono V4 1100 Factory ENG 300 ...

Page 301: ...8 lbf ft Pre coated screw if not pre coated apply 3M SCOTCH GRIP 2353 to thread 3 Flanged hex head flange retaining screws M8x25 6 25 Nm 18 44 lbf ft Lubricate with oil 4 Special screw with index lever fas tening collar M6 1 10 Nm 7 38 lbf ft Loct 243 5 Hex head flange screw for fastening sprocket M10x35 1 50 Nm 36 88 lbf ft Loct 243 6 Screw used to secure the pre selec tor to the crankcase 1 25 N...

Page 302: ...gear on primary shaft 7 Ring 8 Shoulder washer 9 Roller bearing cage for sixth speed gear on primary shaft 10 Sixth speed gear on primary shaft 11 Second speed gear on primary shaft 12 Ring 13 Bearing 14 Selector fork for primary shaft 15 Fork shaft 16 Springs for selector fork shaft 17 Transmission shaft 18 Ball bearing 19 Sprocket Engine Tuono V4 1100 Factory ENG 302 ...

Page 303: ...er bearing cage for fourth speed gear on secondary shaft 33 Shoulder washer 34 Seeger ring 35 Fifth speed gear on secondary shaft 36 Washer 37 First speed gear on secondary shaft 38 Roller bearing cage 39 Washer 40 Selector forks for secondary shaft 41 Fork shaft 42 Springs for selector fork shaft 43 Pin for selector 44 Gearbox shaft 45 Roller bearing cage 46 Index cam plate 47 Ball bearing 48 Bar...

Page 304: ...using Remove the gear sensor from the flywheel side Remove the Seeger ring Remove the water oil pump control gear See also Removing the gear selector Disassembling the clutch Remove the water oil pump control gear driving pin Loosen the screw Engine Tuono V4 1100 Factory ENG 304 ...

Page 305: ...p on the sec ondary shaft from the alternator side to detach the gearbox cover from the crankcase Remove the complete gearbox unit Gearbox shafts Disassembling the gearbox Select neutral and check that the sec ondary shaft does not move when the primary shaft is rotated Remove the gearbox unit Slide off the gearbox primary shaft con trol rod 1 Tuono V4 1100 Factory Engine ENG 305 ...

Page 306: ...rk 2 of the gearbox pri mary shaft Slide off the gearbox secondary shaft control rod 3 Remove the forks 4 of the gearbox secondary shaft Remove both gearbox shafts from the cover Engine Tuono V4 1100 Factory ENG 306 ...

Page 307: ...e shim washer 5 that is lo cated on the secondary shaft between the shaft and the cover Loosen and remove the screw 6 Remove the desmodromic shaft 7 Remove the selector drum 8 Tuono V4 1100 Factory Engine ENG 307 ...

Page 308: ...omic gearbox control rod drum roller cage Lubricate the seat and insert the new roller cage Specific tooling 020863Y Punch assembly cage with rollers desmodromic drum Checking the primary shaft Characteristic Maximum wear limit for selector gear splines 5 3 mm 0 21 in Minimum wear limit of the pinion side primary shaft seat 24 97 mm 0 98 in Minimum wear limit of the clutch side primary and seconda...

Page 309: ...nd wear and replace it if necessary Check the desmodromic bearing 2 for damage and pitting and replace it if necessary Characteristic Maximum selector shaft eccentricity 0 2 mm 0 0079 in Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears Characteristic Maximum endfloat of selector forks 0 05 mm 0 0020 i...

Page 310: ...ace the gearbox forks if it is irregular Assembling the gearbox Place the drum 1 of the gear selector on the support and insert the desmo dromic shaft 2 paying attention to correspond the operations on both components Position and tighten the screw 3 fixing the drum to the desmodromic shaft CAUTION SECURE THE SHIM WASHER 4 TO THE SECONDARY SHAFT WITH GREASE Engine Tuono V4 1100 Factory ENG 310 ...

Page 311: ...nto the support Grease the sliding bushes of the forks Insert the forks 5 in the specific seats of the gearbox secondary shaft Insert the gearbox secondary shaft control rod 6 checking the presence of the springs Tuono V4 1100 Factory Engine ENG 311 ...

Page 312: ...gearbox primary shaft con trol rod 8 Position the special tool from the alter nator side in order to not ruin the edges of the oil seal Insert the gearbox unit in the crank case Specific tooling 0277308 Guide bushing for gearbox secondary shaft Engine Tuono V4 1100 Factory ENG 312 ...

Page 313: ...pump shaft Install the water oil pump control gear Insert the Seeger ring Install the gear sensor making the pin coincide with the slot on the desmo dromic control rod Gear selector Removing the gear selector Drain the engine oil Remove the clutch cover Working from the clutch side remove the selector control shaft Remove the gear locking pawl and re trieve the washer and the spring Tuono V4 1100 ...

Page 314: ...nch assembly cage with rollers gearbox control rod GEARBOX CONTROL ROD OIL SEAL AND ROLLER CAGE SPACER Remove the gearbox control rod spacer Remove the oil seal and the roller cage Install a new gearbox control rod roller cage on the spacer using the specific tool without an adaptor Specific tooling 020862Y Punch assembly cage with rollers gearbox control rod Position a new oil seal on the spacer ...

Page 315: ... Check the selector shaft and its teeth for damage and wear If necessary replace the part Check the lever spring for damage and wear If necessary replace the part Reassembling the gear selector To refit lubricate and carry out the removal operations but in reverse order Starter motor Removing the starter motor Undo the fixing screws 1 of the starter motor collecting the spacers 2 Tuono V4 1100 Fac...

Page 316: ...DOUBLE STARTING GEAR TOOTHING IS DEFORMED IT IS NECESSARY TO ALSO CHECK THE TOOTHING OF THE STARTING MOTOR Check the dual starter gear toothing 1 and the freewheel gear 2 to see if the material is dam aged or deformed For instructions on removing the freewheel gear see the procedure Removing balancer coun tershaft Engine Tuono V4 1100 Factory ENG 316 ...

Page 317: ...Make sure that the woodruff key slot is in perfect condition Remove the needle cage 3 and the roller cage 4 from their housings on the freewheel 2 and check the rollers needles for wear Check for wear on the freewheel sliding surface 2 Fitting the idle gear Fit the intermediate gear Install the clutch cover Tuono V4 1100 Factory Engine ENG 317 ...

Page 318: ...ng SHC fastening screws M5x16 3 5 Nm 3 69 lbf ft 4 Spacers for soundproof cover 3 6 Nm 4 43 lbf ft 5 Soundproof cover fastening screws M6 3 6 Nm 4 43 lbf ft 6 Fastener screws for timing sensor re tainer plate 1 Nm lbf ft Stator SHC fixing screw M6x30 1 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 Removing the flywheel cover Unscrew and remove the three fasten ing screws 1 from...

Page 319: ... three special screws 4 retrieving the relative seal washers Mark the screws 3 appropriately as their lengths are different Remove the cover 5 together with the stator and retrieve the two centring dowels Remove the ThreeBond sealant from the mating surfaces between the cover and the crank case before reassembly Removing the flywheel cover components Unscrew and remove the three screws of the blow...

Page 320: ... RING WHEN REASSEMBLING Remove the seeger ring Remove the shim Remove the oil seal CAUTION DURING REFITTING REPLACE THE OIL SEAL WITH A NEW ONE OF THE SAME TYPE FIT THE NEW OIL SEAL AS INDICATED Engine Tuono V4 1100 Factory ENG 320 ...

Page 321: ...pecific tooling 020914Y Flywheel stop Remove the tool for blocking flywheel rotation Insert a SHC M10x20 screw into the crankshaft hole which will act as a mounting base for flywheel extraction Remove the flywheel using the specific extractor Collect the SHC M10x20 screw Specific tooling 020913Y Flywheel extractor When removing the flywheel with the extractor tool make sure that you retrieve the k...

Page 322: ...bed Remove the three fastener screws of the stator Remove the two fastener screws of the pickup Remove the stator cable retainer plate Remove the stator complete with pick up Disconnect the wiring harness from the cover to complete the removal Engine Tuono V4 1100 Factory ENG 322 ...

Page 323: ...the fastener nut of the pri mary gear and the fastener nut of the countershaft drive gear Remove the lock tool and remove the primary gear Specific tooling 020850Y Primary gear lock Remove the washer and remove the countershaft drive gear freewheel gear taking care not to let the key drop into the engine Separate the freewheel gear from the countershaft drive gear to allow access to the roller bea...

Page 324: ...NG SURFACE Installing the flywheel Before installing the magneto flywheel cover the apertures of the crankcase with a cloth to prevent the retainer key from dropping into the interior of the engine Fit the retainer key on the crankshaft and fit the magneto flywheel aligning the slot with the key Block flywheel rotation using the spe cific tool THE SPECIFIC TOOL MUST BE MODIFIED FOR USE ON THIS ENG...

Page 325: ...a suitable punch tool to install Lubricate the inner part of the oil seal and fit onto the cover oriented correct ly as shown Drive the oil seal fully into its seat using the specific punch tool Specific tooling 020376Y Adaptor handle 020483Y 30 mm guide Fit the shim Fit the circlip Tuono V4 1100 Factory Engine ENG 325 ...

Page 326: ...ck that the two centring pins are correctly in place on the casing Apply a layer of sealing paste along the external edge of the cover Insert the cover together with the sta tor Recommended products Three bond Sealing paste Fit and hand tighten the five screws 1 and the three special screws 2 fitting a washer 3 on every screw Tighten the screws working in stages and diagonally Engine Tuono V4 1100...

Page 327: ...y pipe and se cure the pipe with a new retainer clip Use a new metal clamp if the blow by pipe was disconnected from the fitting on the cover dur ing disassembly Check the seal tightness of the system Clutch side CLUTCH COVER Pos Description Type Quantity Torque Notes 1 Flanged hex cap screw M6x20 1 10 Nm 7 38 lbf ft Tuono V4 1100 Factory Engine ENG 327 ...

Page 328: ...p 1 20 Nm 14 75 lbf ft 5 Spacers for soundproof cover 5 6 Nm 4 43 lbf ft 6 Oil level dipstick 1 3 Nm 2 21 lbf ft 7 Oil load cap 1 5 Nm 3 69 lbf ft CLUTCH Pos Description Type Quantity Torque Notes 1 Flanged nut fixing clutch M20x1 1 150 Nm 110 63 lbf ft Loct 243 2 Clutch springs SHC fixing screw M6x25 6 10 Nm 7 38 lbf ft Removing the clutch cover Drain the engine oil Unscrew and remove the five sc...

Page 329: ...e washers Remove the clutch crankcase Remove the gasket the two alignment pins and the starter idler gear Disassembling the clutch Remove the clutch cover Unscrew and remove the six screws loosening them by a quarter of a turn at a time by stages and working in a diagonal fashion while recovering the washers and the clutch springs Tuono V4 1100 Factory Engine ENG 329 ...

Page 330: ...od Remove the discs Block clutch bell rotation using the spe cific tools Unscrew and remove the clutch hous ing fixing nut Specific tooling 020849Y Clutch retainer tool Remove the two washers and the cup spring washer Engine Tuono V4 1100 Factory ENG 330 ...

Page 331: ... Remove the clutch hub Remove the clutch hub cam tower Remove the washer Remove the clutch bell Tuono V4 1100 Factory Engine ENG 331 ...

Page 332: ... Remove the clutch gear that controls the oil water pumps Remove the needle cage Remove the spacer Remove the thrust bearing Engine Tuono V4 1100 Factory ENG 332 ...

Page 333: ...utch irregular operation If necessary replace the bell Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness Check the primary driven gear for damage and wear and if necessary replace the primary driven gear and the clutch bell all together Make sure there is not excessive noise during op eration if necessary replace the primary drive ge...

Page 334: ...esult in clutch irregular operation If neces sary replace the hub Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS Check the springs for signs of damage and replace them if necessary Measure the free length of the clutch springs and replace them if necessa ry Characteristic Minimum wear limit with individual clutch springs in release position 46 8 mm 1 84 in Engine...

Page 335: ...ng with the collar facing the gearbox Insert the spacer Insert the roller cage Install the clutch gear making it mesh with the oil water pump control gear TURN THE CLUTCH GEAR COLLAR TO FACE THE CLUTCH HOUSING Tuono V4 1100 Factory Engine ENG 335 ...

Page 336: ...aking it engage with the engine pinion Insert the washer Install the clutch hub cam tower Position the clutch hub INSTALL THE THREE CLUTCH HUB CAMS IN THE RE SPECTIVE CLUTCH BASKET INCLINES Engine Tuono V4 1100 Factory ENG 336 ...

Page 337: ...tation using the appropriate tool Tighten the clutch housing fixing nut Specific tooling 020849Y Clutch retainer tool Insert the disc with friction material and the black tooth into the bell Insert one of the metal discs into the bell Tuono V4 1100 Factory Engine ENG 337 ...

Page 338: ...sher Insert the spring washer with the con cave side facing out Insert the disc covered with friction ma terial into the housing Insert the nitrided metal disc into the clutch housing Engine Tuono V4 1100 Factory ENG 338 ...

Page 339: ...a metal disc with one with friction material end ing with a friction material disc with a black tooth Place the control rod together with the thrust bearing and the shim washer Fit the thrust plate Tuono V4 1100 Factory Engine ENG 339 ...

Page 340: ...stalling the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING Before carrying out the removal of the bushing it is necessary to thread the inside to allow the extractor to tighten sufficiently Warm up the cover Using a generic extractor it is then possible to remove the bushing from the cover Engine Tuono V4 1100 Factory ENG 340 ...

Page 341: ... clutch bushing Then insert the tool to push the bushing into the seat until it stops Position the starting transmission gear on the crankcase Position the gasket and the two dowel pins in the clutch cover Insert the clutch cover making sure to have correctly engaged the clutch con trol lever and the rack shaft Insert the five special screws 5 and the eleven fastening screws 6 around the perimeter...

Page 342: ... fit the five fastener screws 8 and then tight en the screws to the specified torque Fill with engine oil to the correct level Heads VALVES COVER Pos Description Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 38 lb ft Engine Tuono V4 1100 Factory ENG 342 ...

Page 343: ...am shaft cam tower fixing screws M6x45 20 11 Nm 8 11 lb ft 3 Reed valve covers fixing screws 6 6 Nm 4 43 lb ft 4 Water outlet coupling fixing screw 2 10 Nm 7 38 lb ft Pre impregnated or else Loct 270 or Loct 648 5 Flanged head nut 12 30 55 Nm 22 13 40 57 lb ft Lubricate the head and under the head 6 Head tightening screw chain side M6x55 4 12 Nm 8 85 lb ft Lubricate the head and under the head Tuo...

Page 344: ...in tensioner sliders fastening screws M8 2 20 Nm 14 75 lb ft Loct 243 3 Chain guide sliders fixing screws M6x18 2 10 Nm 7 38 lb ft Loct 243 Head cover removal The procedure described as follows is for a single cylinder head but is valid for both heads Unscrew and remove the three screws with the relative rubber washers Engine Tuono V4 1100 Factory ENG 344 ...

Page 345: ...he area indicated in the figure Recommended products Three bond Sealing paste Smear the head surface with suitable sealant in the area indicated in the fig ure Recommended products Three bond Sealing paste Fit the head cover Tighten the three screws with rubber washers to the prescribed tightening torque Front head Tuono V4 1100 Factory Engine ENG 345 ...

Page 346: ...to the primary gear fas tener nut Position cylinder 1 piston LH rear pis ton so that it is at the point where it crosses TDC Unscrew and remove the first screw of the camshaft drive sprocket rotate the crankshaft 150 in the engine rotation direction direction of travel Insert the pin from the flywheel side in to the hole in the crankshaft Specific tooling 020852Y Crankshaft timing pin Fit the pin ...

Page 347: ...nd remove the three screws 1 and remove the bearing cap 2 and the oil pipe 3 Install the specific camshaft gear sup port tool Fasten to the head with the two screws Specific tooling 020956Y Support for camshaft gear on head Remove the second screw of the cam shaft drive sprocket Tuono V4 1100 Factory Engine ENG 347 ...

Page 348: ...ke and exhaust cam shafts If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK Check that the camshaft gear works properly if it is damaged or does not move smoothly replace the timing chain and the camshaft gear CAMSHAFT LOBES Ch...

Page 349: ...e timing chain guide sliders for damage If necessary replace the parts Installing camshafts NOTE THE INTAKE AND EXHAUST CAMSHAFTS ARE BOTH DEDICATED FOR THE FRONT AND REAR CYLINDER BANKS NOTE THE INTAKE AND EXHAUST CAMSHAFTS OF THE FRONT CYLINDER BANK ARE IDENTIFIED BY TWO LINES IN THE POSITIONS INDICATED Refit the camshafts ensuring that they are aligned correctly If the two camshafts are timed c...

Page 350: ...e holder tool and onto the camshaft CAUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM SHAFT Apply Loctite 243 thread lock adhesive to the first screw of the camshaft sprocket and hand tighten the screw only Fit the bearing cap the oil pipe and the three fastener screws Tighten the ten fastener screws of the camshafts tightening in progressive steps in a ...

Page 351: ...eplaced with a new component at each reassembly and tighten the screw to the specified tor que Continue rotating the crankshaft in di rection of rotation of engine to bring it back to the previous position in which the holes in the camshaft and the bear ing cap were aligned insert the refer ence pin while checking with the crank shaft reference pin that the flywheel side hole and the hole on the c...

Page 352: ... the chain sliders screws Remove the chain sliders Unscrew and remove the two head fas tener screws a b from the flywheel side Loosen the six nuts on the stud bolts proceeding in the following order 6 5 4 3 2 1 After loosening all nuts remove them in order indicated above Remove the front head slipping it off the stud bolts Collect the gasket and the two dowel pins Engine Tuono V4 1100 Factory ENG...

Page 353: ...ten sioner tool See also Removing camshafts Front head check Check that The contact surfaces with the cover and the crankcase are not scored or damaged so they jeopardise a perfect seal Check the status of the valve seats Check that the routing of the oil pipes is free and if required clean them by blowing a jet of compressed air Front head fitting Follow the procedure described below to install t...

Page 354: ...orrectly This washer is available as a spare part Fit the washer onto the front chain ten sioner then install the chain tensioner in the relative seat in the crankcase ensuring that it is oriented correctly Take particular care during this step to ensure that the washer fits correctly in place if the washer is bent or not seat ed in the correct position the operation of the timing system will be c...

Page 355: ...retighten the six nuts on the stud bolts proceeding in the following order 1 2 3 4 5 6 Then tighten them fully following the same order Tighten the two screws according to the sequence a b NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY Tuono V4 1100 Factory Engine ENG 355 ...

Page 356: ...E AND EXHAUST CAMSHAFTS OF THE FRONT CYLINDER BANK ARE IDENTIFIED BY TWO LINES IN THE POSITIONS INDICATED Check the number engraved on the U bolts which must correspond with the one engraved on the head If the U bolts between the two heads are inverted camshaft seizure may oc cur IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT IF NECESSARY REPLACE THE ENTIRE HEAD Fit the U bolts with nine O rings an...

Page 357: ...ton to TDC in the valve overlap position rotate the crankshaft 150 in the engine rotation direction direction of travel insert the respective pin from the fly wheel side into the groove on the crankshaft Specific tooling 020852Y Crankshaft timing pin Reposition the sprocket on the cam shaft with timing hole and the hole for the fastener screw of the sprocket aligned with the slot in the sprocket I...

Page 358: ...ly tighten the gear fix ing screw on the camshaft Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the second screw of the sprocket is revealed Block crankshaft rotation using one of the specific tools Apply Loctite 243 thread lock on the thread of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix ing ...

Page 359: ...pecific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Rear head Removing camshafts To remove the camshafts of the rear head follow the procedure described below Remove both cylinder head covers the soundproofing covers the alternator side cover and the clutch cover Move cylinder piston 1 left rear piston to the TDC Start rotating the crankshaft in the di rection of rotation of ...

Page 360: ...e hole in the crankshaft Specific tooling 020852Y Crankshaft timing pin Fit the pin for aligning the intake cam shaft with the hole in the bearing cap Specific tooling 020851Y Camshaft timing pin Loosen the second screw of the cam shaft drive sprocket Remove the pin from the camshaft drive sprocket Unscrew and remove the three screws 1 and remove the bearing cap 2 and the oil pipe 3 Engine Tuono V...

Page 361: ...e two screws Specific tooling 020956Y Support for camshaft gear on head Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool s spacer Unscrew the seven screws in progres sive steps in a criss cross pattern and remove Retrieve the copper washers from the screws near the spark plug holes Remove the bearing caps complete with O rings and alignment pins Tuo...

Page 362: ...MSHAFT LOBES Check that they do not show blue colouring cracks or scratches otherwise replace the camshaft gear and chain Fasten the camshaft horizontally as shown in the figure and make it spin to check the eccentricity with a dial gauge if necessary replace the part Characteristic Maximum camshaft axial clearance intake outlet 0 3 0 1 mm 0 012 0 004 in Check the timing chain for damage or stiffn...

Page 363: ...aust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Fit the bearing caps complete with O rings and alignment and fit and hand tighten the seven screws indicated Use new copper washers on the four screws near the spark plug holes Loosen the camshaft sprocket lock screw on the tool Slide the sprocket off the holder tool and onto...

Page 364: ... on the bearing cap and fit the pin Tighten the first fastener screw of the camshaft sprocket to the specified tor que Specific tooling 020851Y Camshaft timing pin Remove the two crankshaft and cam shaft reference pins Rotate the crankshaft in direction of engine rotation only as far as neces sary to reveal the second fastener hole for the sprocket Apply Loctite 243 thread lock adhesive to the thr...

Page 365: ... operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Check if the clearance between the cam on the shaft and the tappet is correct If not repeat the valve clearance adjustment procedure Rear head removal In order to remove the rear head the procedures described in the paragraph Removing the cam shafts rear head must be performed beforehand Then proceed as describe...

Page 366: ...stud bolts Collect the gasket and the two dowel pins Remove the chain tensioner complete with O ring using the specific tool If the O ring is not on the chain ten sioner make sure it was not left in the crankcase seat REPLACE THE O RING UPON EACH REMOVAL Specific tooling 020883Y Fitting removing timing chain ten sioner tool Rear head check Check that Engine Tuono V4 1100 Factory ENG 366 ...

Page 367: ... blowing a jet of compressed air Rear head fitting Follow the procedure described below to install the rear cylinder head Install a new O ring on the chain ten sioner REPLACE THE O RING UPON EACH REMOVAL Compress the chain tensioner com pletely making sure that the total length is 40 05 0 5 mm 1 58 0 02 in Insert the chain tensioner into the crankcase being careful to position it correctly Tuono V...

Page 368: ...retighten the six nuts on the stud bolts proceeding in the following order 1 2 3 4 5 6 Then tighten them fully following the same order Tighten the two screws according to the sequence a b NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY Engine Tuono V4 1100 Factory ENG 368 ...

Page 369: ...E AND EXHAUST CAMSHAFTS OF THE FRONT CYLINDER BANK ARE IDENTIFIED BY TWO LINES IN THE POSITIONS INDICATED Check the number engraved on the U bolts which must correspond with the one engraved on the head If the U bolts between the two heads are inverted camshaft seizure may oc cur IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT IF NECESSARY REPLACE THE ENTIRE HEAD Fit the U bolts with nine O rings an...

Page 370: ...rear piston to TDC in the valve overlap position rotate the crankshaft 450 in the engine rotation direction direction of travel Insert the pin from the clutch side into the hole in the crankshaft Specific tooling 020852Y Crankshaft timing pin Reposition the sprocket on the cam shaft with timing hole and the hole for the fastener screw of the sprocket aligned with the slot in the sprocket Insert th...

Page 371: ...ly tighten the gear fix ing screw on the camshaft Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the second screw of the sprocket is revealed Block crankshaft rotation using one of the specific tools Apply Loctite 243 thread lock on the thread of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix ing ...

Page 372: ...e clutch side hole and the hole in the crankshaft are perfectly aligned If this is not the case repeat the timing operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Valves Valve removal Remove the head Place the head on supporting surface Number the valves and their bucket tappets in order to position them correctly upon refitting Extract the bucket tappets Extra...

Page 373: ...Y Compresses intake valve springs 020854Y Compresses exhaust valve springs See also Front head removal Rear head removal Remove the cotters using a magnet Release the valve springs Remove the upper cap and the springs CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE AS THE EXHAUST VALVES HAVE A SINGLE SPRING Tuono V4 1100 Factory Engine ENG 373 ...

Page 374: ... perpen dicular directions and position the dial gauge as shown in the figure Characteristic Valve stem distortion 0 25 mm 0 0098 in If the valve stem when measured with a micro meter is worn to its limit and the clearance ex ceeds the specified limit replace the valve Recheck the clearance after replacing the valve Characteristic Intake valve stem diameter 4 985 4 965 mm 0 1963 0 1954 in Exhaust ...

Page 375: ...ad face and measure the eccentricity If the eccentricity exceeds the specified limit re place the valve Characteristic Valve head eccentricity 0 03 mm 0 0012 in Coating may get slightly damaged in the indicated area Valve installation The intake valves are fitted with dual springs while he exhaust valves only have a single spring The intake valve springs are marked blue 1 and the exhaust springs 2...

Page 376: ...E A DOUBLE SPRING WHERE AS THE EXHAUST VALVES HAVE A SINGLE SPRING Fit the caps Compress the valve springs with the specific wrench and with the spring compressing tool Insert the cotters into the seat Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs Engine Tuono V4 1100 Factory ENG 376 ...

Page 377: ... Release the wrench checking that the cotters are positioned correctly in the valve grooves Position the adjusting shims Position the bucket tappets Tuono V4 1100 Factory Engine ENG 377 ...

Page 378: ... 7 Flanged TE screw fixing fuel rail gearbox lubrication M6x12 2 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 8 TB TORX fixing screw of the con necting rods lubrication nozzles 4x12 4 5 Nm 3 69 lbf ft Pre impregnated screw in absence Loct 2045 9 TSPEI screw fixing bearing stop plates M6x16 2 10 Nm 7 38 lbf ft Loct 243 10 Stud bolt M6 1 Bring to 33mm from the surface Loct 648 1...

Page 379: ... 6 Nm 4 43 lbf ft IGNITION UNIT Pos Description Type Quantity Torque Notes 1 Hex headed nut cl 10 type 2 iso 8674 M10x1 1 50 Nm 36 88 lbf ft Loct 243 2 Starter motor SHC fastener screw M6x40 2 10 Nm 7 38 lbf ft Screw fastening cables to the starter motor M6 1 6 Nm 4 43 lbf ft Tuono V4 1100 Factory Engine ENG 379 ...

Page 380: ...HC fixing screw M6x30 3 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 5 Fastener screws for pick up retainer plate 2 6 Nm 4 43 lbf ft Pre impregnated screw and in ab sence Loct 2045 Balancing countershaft removal In order to remove the balancer countershaft the clutch cover alternator cover and complete clutch must be removed beforehand Then proceed as described Fit the special...

Page 381: ... gear Remove the lock tool and remove the primary gear Specific tooling 020850Y Primary gear lock Remove the washer and remove the countershaft drive gear freewheel gear taking care not to let the key drop into the engine Remove the key from the countershaft Tuono V4 1100 Factory Engine ENG 381 ...

Page 382: ...tall the balancer countershaft follow the pro cedure described below Fit the balancer countershaft into the casing from the flywheel side Working from the clutch side fit the spacer onto the countershaft ensuring that the spacer is installed the right way around as shown Engine Tuono V4 1100 Factory ENG 382 ...

Page 383: ...ION MAKE SURE THAT THE KEY IS INSTALLED AND SEATED CORRECTLY AS SHOWN Fit the washer and the fastener nut of the countershaft drive gear CAUTION MAKE SURE THAT THE KEY IS INSTALLED AND SEATED CORRECTLY AS SHOWN Fit the special primary gear lock tool Fit the primary gear fastener nut and then tighten both nuts of the gears to the specified torque Specific tooling 020850Y Primary gear lock Tuono V4 ...

Page 384: ...and remove the fastener nut of the primary gear Remove the lock tool and remove the primary gear Specific tooling 020850Y Primary gear lock Installing the primary drive gear To install the primary gear follow the procedure described below Fit the primary shaft gear onto the crankshaft ensuring that it is aligned correctly with the countershaft drive gear Align the markings on the respec tive teeth...

Page 385: ...ator water pump gearbox unit primary drive shaft gear both timing chains the chain sliders oil sump the gear selector pin spacer starter motor and intermediate gear countershaft See also Magneto flywheel removal Water pump Disassembling the gearbox Main transmission gear removal Front head removal Rear head removal Removing the oil sump Balancing countershaft removal Tuono V4 1100 Factory Engine E...

Page 386: ...ward and loosen the screws in the following order 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 After loosening all screws remove them in order indicated above Loosen the six nuts on the stud bolts proceeding in the following order 6 5 4 3 2 1 After loosening all nuts remove them in order indicated above Engine Tuono V4 1100 Factory ENG 386 ...

Page 387: ... heads Open the crankcases Install the tool that keeps the crank shaft in position Specific tooling 020857Y Crankshaft support U bolt Unscrew and remove the two connect ing rod screws Remove the connecting rod cap NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the piston connected to the connecting rod from the cylinder side Take out the Seeger ring Tuono V4 1100 Factory Engine EN...

Page 388: ...eads were removed position the specific special tool to keep the pis tons from coming out Specific tooling 020858Y Maintenance of the pistons in the cyl inders Unscrew and remove the eight con necting rod screws Remove the four connecting rod caps NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Engine Tuono V4 1100 Factory ENG 388 ...

Page 389: ...ove the countershaft FLYWHEEL SIDE Unscrew and remove the bearing re tainer screw Remove the lock Heat up the crankcase to 150 C 302 F Position the general tool to pull out bearings Remove the bearing CLUTCH SIDE Unscrew and remove the bearing re tainer screw Remove the lock Tuono V4 1100 Factory Engine ENG 389 ...

Page 390: ...haracteristic Maximum crankshaft axial clearance after closing the crankcase 0 5 mm 0 0197 in Maximum radial clearance between the main bearings and the crankshaft pins 0 07 mm 0 00276 in Balancing countershaft check Characteristic Maximum countershaft axial clearance after closing the crankcase 0 1 mm 0 0039 in Engine Tuono V4 1100 Factory ENG 390 ...

Page 391: ...0 027 0 045 mm 0 025 0 043 mm CAUTION THE MEASUREMENT OF THE PISTON DIAMETER IS PER FORMED AT 6 mm 0 24 in FROM ITS BASE Characteristic Coupling clearance between the pin and the hole on the piston 0 016 0 005 mm 0 0006 0 0002 in Aperture tolerance of the first piston ring mounted on the cylinder 0 10 0 25 mm 0 0039 0 0098 in Aperture tolerance of the second piston ring mounted on the cylinder 0 4...

Page 392: ...sted in the following table CRANKSHAFT CONNECTING ROD BALANCING CLASSES Crankshaft balancing classes Combinations of weight classes for connecting rod pair on alternator side Combinations of weight classes for connecting rod pair on primary drive side AA AA AA AA AA BB BB BB AA CC BB BB AA CC CC CC CC BB DD CC CC DD BB DD DD DD CC EE DD DD EE CC EE EE EE EE EE paired selections of mountable weight...

Page 393: ...ses are available A B C which differentiate in the diameter of the hole in the bearings The category is marked on the crankcase on the right side in the area below the gearbox Different classes of bearings can be used e g A B C or B B C or A B A A number that indicates the position of the main journal is stamped on the crankcase 1 flywheel side 2 central 3 clutch side Tuono V4 1100 Factory Engine ...

Page 394: ...asses CRANKSHAFT CATEGORIES Specification Desc Quantity Class C Main journals diameter 46 028 46 023 mm 1 8121 1 8119 in Class D Main journals diameter 46 023 46 018 mm 1 8119 1 8117 in Class E Main journals diameter 46 018 46 013 mm 1 8117 1 8115 in Once the categories below are checked 1 crankcase 2 flywheel side main journal 3 centre main journal 4 clutch side main journal Choose the bushings u...

Page 395: ...rnal Bushing yellow Bushing yellow Bushing blue Class D main journal Bushing green Bushing yellow Bushing yellow Class E main journal Bushing green Bushing green Bushing yellow CRANKSHAFT BUSHINGS CONNECTING RODS Three types of semi bushing are available for the connecting rods Tuono V4 1100 Factory Engine ENG 395 ...

Page 396: ...Required clearances class 2 X 35 885 35 880 mm Blue Yellow 1 Yellow Yellow 0 053 0 026 mm 0 053 0 027 mm Y 35 880 35 874 mm Yellow Yellow Yellow Green 1 0 054 0 026 mm 0 054 0 027 mm Z 35 874 35 869 mm Yellow Green 1 Green Green 0 054 0 027 mm 0 054 0 028 mm Key 1 If using bushing of different thickness install the thickest on the side of the connecting rod shank BIG END BUSHING REPLACEMENT PROCED...

Page 397: ...0376Y Adaptor handle Position the new bearing with its groove on the outside diameter facing outward with respect to the crankcase In this way it will be possible to install the bearing retainer in the groove Using the suitable tools fit the bearing in the crankcase until tool stops Fit the retainer in the bearing groove Tighten the bearing retainer screw CLUTCH SIDE Tuono V4 1100 Factory Engine E...

Page 398: ...w bearings with their groove on the outside diameter facing outward with respect to the crankcase In this way it will be possible to install the bearing retainer in the groove Using the suitable tools fit the bearing in the crankcase until tool stops Fit the retainer in the bearing groove Tighten the bearing retainer screw Install the balancing countershaft Engine Tuono V4 1100 Factory ENG 398 ...

Page 399: ... with the larger diameter side facing towards the exterior of the engine Fit the primary shaft gear onto the crankshaft ensuring that it is aligned correctly with the countershaft drive gear Align the markings on the respec tive teeth to align the gears correctly NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR Fit th...

Page 400: ... pistons have two selections A and B Therefore they are coupled with the cylinder ac cording to the selection of the latter which is marked on the upper crankcase halves Pre assemble the pistons on the workbench with the connecting rod shank and the relative semi bushing The pre assembly procedure is identical for all four pistons and must be done as follows with the piston crown parallel to the w...

Page 401: ...he piston crown towards the exhaust the bevel ling on the connecting rod head must face outward of its crank pin Specific tooling 020980Y Piston assembly ring Remember to couple the connecting rod shank and cap correctly combin ing the respective numerical referen ces Use new connecting rod screws lubri cating the thread and under the head Proceed with tightening according to the procedure describ...

Page 402: ...dowels in the crankcase Insert a new oil seal O ring in the spe cific seat Insert the maximum pressure valve in the crankcase composed of two sep arate parts Apply a layer of sealing paste along the external edge of the crankcase Join the two crankcases Recommended products Three bond Sealing paste Engine Tuono V4 1100 Factory ENG 402 ...

Page 403: ...he following order 1 2 3 4 5 6 Then tighten them fully following the same order Pre tighten the screws in the following order 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Then tighten them fully following the same order Tuono V4 1100 Factory Engine ENG 403 ...

Page 404: ... lb ft Tighten to torque unscrew and re tighten to torque 4 Oil pipes coupling fastening screw M6 1 10 Nm 7 38 lb ft Loctite 243 5 Screws used to fasten the pump to the crankcase M6 5 10 Nm 7 38 lb ft 6 Oil pressure sensor fastening 1 15 Nm 11 06 lb ft 7 Oil filter fastening 1 15 Nm 11 06 lb ft 8 Screws used to fasten the pump to the crankcase M6 1 10 Nm 7 38 lb ft 9 Oil return pipe fastening scre...

Page 405: ...the head and under the head 5 Crankcase fastening screws M8 3 25 Nm 18 44 lb ft Lubricate with oil Lubricate the head and under the head 6 Crankcase fastening screw M8 1 25 Nm 18 44 lb ft Lubricate with oil Lubricate the head and under the head 7 Crankcase fastening screws M6 8 10 Nm 7 38 lb ft Lubricate the head and under the head 8 Crankcase fastening screw M6 1 10 Nm 7 38 lb ft Lubricate the he...

Page 406: ...TION IT IS IMPOR TANT TO CHECK THAT THE OIL DELIVERY HOLES ARE NOT BLOCKED To remove the lubrication jets simply remove the retaining screw and then extract them from their housings tak ing care not to lose the rubber O ring To remove the lubrication pipe simply remove the retaining screws and then extract it from its housing taking care not to lose the rubber O ring Oil pump Removing Remove the g...

Page 407: ...oving the gearbox Water pump Unscrew and remove the four cooling oil pump cover screws Remove the cooling oil pump cover Collect the two dowel pins Remove the external rotor from the cover Remove the internal oil cooling rotor Collect the hitch pin Tuono V4 1100 Factory Engine ENG 407 ...

Page 408: ...rews Remove the lubrication oil pump cover and the intermediate pump casing from the shaft Collect the two dowel pins Remove the external lubrication rotor Remove the internal oil lubrication ro tor Collect the drive spindle Engine Tuono V4 1100 Factory ENG 408 ...

Page 409: ...om the side with the Seeger ring seat for fasten ing the gear Install the drive spindle on the shaft Position the external rotor on the lubri cation pump s internal rotor Position the dowel pins Position the pump cover and the inter mediate pump casing on the lubrica tion pump s external rotor To check that the intermediate casing is oriented correctly check the gasket seat Tuono V4 1100 Factory E...

Page 410: ... pump control shaft Position the oil cooling pump s internal rotor Position the dowel pins and the exter nal rotor on the cooling oil pump cover Fit the pump cover on the internal rotor Tighten the four cooling oil pump cover screws Fit a new gasket Engine Tuono V4 1100 Factory ENG 410 ...

Page 411: ...Removing the oil sump Drain the engine oil Unscrew and remove the twelve oil sump screws Remove the oil sump Remove the upper gasket Tuono V4 1100 Factory Engine ENG 411 ...

Page 412: ...Y OVER HAULED OR IN CASE OF PROBLEM WHICH MAY HAVE GENERATED SUSPENDED DEBRIS IN THE OIL DURING REFITTING REPLACE THE GASKET WITH A NEW ONE OF THE SAME TYPE Remove the metal gasket central fixing screw Remove the metal gasket Remove the lower gasket Remove the overpressure valve together with gasket Engine Tuono V4 1100 Factory ENG 412 ...

Page 413: ...il vapours exit from the fitting 2 on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump SAS valve SECONDARY AIR SYSTEM Pos Description Type Quantity Torque Notes 1 Cylindrical head hex socket secon dary air solenoid screws M6x16 2 10 Nm 7 38 lbf ft Tuono V4 1100 Factory Engine ENG 413 ...

Page 414: ...are twofold the catalytic converter reaches the op erating temperature more quickly it permits the use of richer mixtures in some critical conditions e g at idle or low engine speeds Inspecting the one way valve Unscrew and remove the three screws Remove the cover together with the two secondary air system valves Engine Tuono V4 1100 Factory ENG 414 ...

Page 415: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 416: ...tors on the rear throttle body 2 Lower injectors on the front throttle body 3 Connection 4 Front throttle body 5 Rear throttle body 6 Fuel tank 7 Fuel pump 8 Engine EVAPORATIVE EMISSIONS CONTROL SYSTEM LAYOUT Power supply Tuono V4 1100 Factory P SUPP 416 ...

Page 417: ...3 ECU 4 T connection 5 Lower injectors on the rear throttle body 6 Lower injectors on the front throttle body 7 Fuel tank 8 Canister 9 Front throttle body 10 Rear throttle body Fuel pump Tuono V4 1100 Factory Power supply P SUPP 417 ...

Page 418: ...litate removal of the fuel pump remove the mount by unscrewing the fastener screw Remove the safety plate Press the release buttons on both sides of the connector and disconnect the connector from the fitting on the fuel pump Unscrew and remove the six fastener screws of the fuel pump Power supply Tuono V4 1100 Factory P SUPP 418 ...

Page 419: ... Ease out the pump taking particular care not to damage the pump Injection Tuono V4 1100 Factory Power supply P SUPP 419 ...

Page 420: ...Diagram Key 1 Electronic suspension control unit where applicable 2 Demand sensor 3 Exhaust valve motor 4 ECU Power supply Tuono V4 1100 Factory P SUPP 420 ...

Page 421: ... their engines but actually a specific torque The Ride by Wire system has been so designed that the throttles of the throttle bodies are mechanically isolated from the throttle control their actuation depends exclusively on 2 electrical motors controlled by the control unit The control unit refers to specific handle maps to determine by how much and how quickly the throttle valves are opened The p...

Page 422: ...jector Checking the wiring harness and the connections The injectors may be activated to check that they are working correctly from the menu SELF DIAGNOSIS ACTIVATION FUNCTIONS ACTIVATE INJECTOR of the diagnostic tool Removing the throttle body Completely remove the air filter box Disconnect the injector fuel pipe Release the snap fit clamp on the col lars from the engine NOTE DO NOT RELEASE THE C...

Page 423: ... tests are performed on the throttle body assembly by the control unit during vehicle oper ation with the results visible on the diagnostic instrument The only action possible before replacing the com ponent is checking the connectors and cable har nesses Installing the throttle body When installing the throttle body refer to the electrical system section for the correct cable routing Ensure that ...

Page 424: ...eed by controlling the throttle body motors directly As a result idle speed adjustment and maintenance of the components involved in idle speed regulation stepper mo tors thermoactuators etc are not necessary Power supply Tuono V4 1100 Factory P SUPP 424 ...

Page 425: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 426: ...LINS ASC TUONO V4 1100 FACTORY Pos Description Type Quantity Torque Notes 1 Calliper mounting bracket fixing screws M6 2 2 10 Nm 7 37 lbf ft 2 ABS sensor fixing screw M5 1 8 Nm 5 90 lbf ft Suspensions Tuono V4 1100 Factory SUSP 426 ...

Page 427: ...g is adjusted to suit most high and low speed riding conditions whether the vehicle is partially or fully loaded However the setting can be modified for specific needs according to vehicle use RACING TRACK SETTINGS MUST BE DONE ONLY FOR OFFICIAL COMPETITIONS OR SPORTS EVENTS WHICH ARE IN ALL CASES AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES IT IS STRICTLY F...

Page 428: ...ew 1 Unscrew 10 clicks from fully closed Compression damping adjustment screw 2 Unscrew 10 clicks from fully closed Spring pre loading nut 3 screw 0 turns from fully open Stanchion protrusion A from top yoke excluding cover 1 notch 4 mm 1 notch 0 15 in RACING ADJUSTMENT TRACK USE ONLY Specification Desc Quantity Rebound damping adjustment screw 1 Unscrew 4 clicks from fully closed Compression damp...

Page 429: ...RK ACCORD ING TO THE VEHICLE USE CONDITIONS BY INCREASING THE SPRING PRE LOAD THE CONTROL PARAMETERS OF THE FRONT FORK MUST BE ADJUS TED BY INCREASING THEIR VALUES TO AVOID UNEX PECTED JOLTS WHILE DRIVING The forks can be adjusted as follows Standard adjustment Spring pre load 2 5 turns from the adjustment ring nut completely unscrewed ASC mode A2 M2 A3 M3 Stems A protrusion from top plate 2 notch...

Page 430: ...ings and the front body work THE FOLLOWING OPERATIONS REFER TO A STANCHION BUT APPLY TO BOTH FOR VERSION WITH ELECTRONIC SUSPEN SION ONLY WORKING WITH PARTICULAR CARE DISCONNECT THE CONNECTOR FROM THE FORK CAP Loosen the screws on the lower plate While supporting the stanchion loosen the screw on the top plate Extract and remove the stanchion Suspensions Tuono V4 1100 Factory SUSP 430 ...

Page 431: ...apter Draining oil TUONO V4 1100 NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS Using the appropriate tool fasten the fork in the vice Specific tooling AP8140149 Guard for assembly operations Operating on the upper screw unload the spring Loosen the cover without unscrewing it completely Tuono V4 1100 Factory Suspensions SUSP 431 ...

Page 432: ...ing AP8140149 Guard for assembly operations Using the specific tool fixed to the pre loading pipe compress the spring Insert a spanner in the lock nut of the cover Specific tooling 020888S Pre load tube clamp Unscrew the cap and remove it Remove the spring preload pipe Suspensions Tuono V4 1100 Factory SUSP 432 ...

Page 433: ... to collect fluids DO NOT DISPOSE OF OIL IN THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE TUONO V4 1100 FACTORY NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS FORKS Set the pre loading spring to the mini mum position Tuono V4 1100 Factory Suspensions SUSP 433 ...

Page 434: ...ng a wrench in order to release the upper nut on the spring retaining ring Unscrew the upper adjustment cap us ing the special Ohlins tool Specific tooling 01761 04 Ohlins fork cap ring nut Remove the complete cap Unscrew the nut and remove it exert ing slight pressure on the pre loading spring Suspensions Tuono V4 1100 Factory SUSP 434 ...

Page 435: ...e pre loading tube come out Disassembling the fork TUONO V4 1100 NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS Discharge the fork remove the internal dipstick of the pumping member pin 1 and the washer 2 Operate repeatedly on the pumping member pin 3 so as to drain com pletely the oil from inside Tuono V4 1100 Factory Suspensions SUSP 435 ...

Page 436: ...amage the sleeve rim Remove the retainer ring Take out the sleeve from the stem using the stem as a hammer puller Remove the fixed bushing 1 the movable bushing 2 the ring 3 and the oil seal 4 from the stem Remove the lock seeger ring of the spring guide Remove the spring guide Suspensions Tuono V4 1100 Factory SUSP 436 ...

Page 437: ...ic tooling 020889Y Wrench for locking pumping unit ring nut Remove the pumping member pin TUONO V4 1100 FACTORY NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS FORKS Remove the pre loading tube Remove the wheel holder shaft 1 and the sleeve 2 Tuono V4 1100 Factory Suspensions SUSP 437 ...

Page 438: ... 5 Replace the following components with new ones shaft seal 5 anti dust seal 3 CAUTION PROCEED WITH EXTREME CAUTION IN ORDER TO PREVENT FOREIGN BODIES FROM EN TERING THE SLEEVE OR THE WHEEL HOLDER SHAFT DO NOT REUSE THE OIL THAT WAS DRAINED EARLIER Checking the components TUONO V4 1100 NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS stanchion Check that the sliding surface is not scratched...

Page 439: ... cracks if it is damaged replace it Spring Check the condition of the spring making sure that the length is within the acceptable limits If not replace the spring MINIMUM LENGTH OF FREE SPRING 265 mm 10 4 in Check the condition of the following components upper bushing lower bushing plunger If there is evidence of excessive wear or damage replace the component concerned CAUTION REMOVE ANY IMPURITI...

Page 440: ...00787 in Sleeve Check for damage and or cracks if it is damaged replace it Springs Check the condition of the springs making sure that the length is within the acceptable limits If not replace the springs MINIMUM LENGTH OF FREE SPRING 260 mm 10 24 in Reassembling the fork TUONO V4 1100 NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STE...

Page 441: ...it the sleeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling AP8140189 Tool for mounting the oil seal for holes with diam 43 mm 1 69 in AP8140146 Weight Insert the retainer ring in its position Tuono V4 1100 Factory Suspensions SUSP 441 ...

Page 442: ...r lock the pump ing member pin and tighten the fixing screw on the fork end to the prescribed torque Specific tooling 020889Y Wrench for locking pumping unit ring nut Insert the spring guide and lock it in place using the respective snap ring Position the forks vertically Insert the base washer TUONO V4 1100 FACTORY NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS FORKS Suspensions Tuono V4 1100 ...

Page 443: ...ve 2 Position the two halves of the special tool on the shaft 1 behind shaft seal 5 together with the respective buffer Grip the special tool and push the shaft seal 5 into its housing on the sleeve 2 Remove the tool Specific tooling AP8140189 Tool for mounting the oil seal for holes with diam 43 mm 1 69 in AP8140146 Weight Insert the retaining ring 4 into its housing on the sleeve 2 Tuono V4 1100...

Page 444: ... oil TUONO V4 1100 NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS Place the sleeve upright in a vice fitted with protection shoes Compress the sleeve in the stanchion Place a support under the stanchion in order to leave it compressed Pour part of the fork oil into the sleeve Wait a few minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Measure the ai...

Page 445: ...G THE SPRING AND ENSURE THAT THE PART WHERE THE SPI RAL IS MORE COMPRESSED IS FACING DOWNWARDS Insert the washer that will be supported on the spring Insert the nut on the plunger and hand tighten it Position the pre loading tube Screw the special tool onto the plunger shaft and maintain it in the raised po sition as long as possible in order to insert a wrench on the nut while com pressing the sp...

Page 446: ...tanchion Place a support under the stanchion in order to leave it compressed Pour part of the fork oil into the sleeve Wait a few minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIO...

Page 447: ...h stems Insert the pre load tube in the stanchion making sure that it is aligned correctly Insert the spring CAUTION PROCEED WITH CAUTION WHEN INSERTING THE SPRING AND ENSURE THAT THE PART WHERE THE SPI RAL IS MORE COMPRESSED IS FACING DOWNWARDS Position the ring nut on the preload spring and keeping it compressed screw the lock nut on the pumping el ement Tuono V4 1100 Factory Suspensions SUSP 44...

Page 448: ...t stops Using the special Ohlins tool tighten the cap to the prescribed torque Steering damper STEERING Pos Description Type Quantity Torque Notes 1 Screws fastening raiser to upper steering yoke M10 2 50 Nm 36 88 lbf ft Loctite 243 Suspensions Tuono V4 1100 Factory SUSP 448 ...

Page 449: ...ng shock absorber to the upper yoke M6 1 10 Nm 7 38 lbf ft Loctite 243 10 Screw used to fasten the steering shock absorber to the stand off M6 1 10 Nm 7 38 lbf ft Loctite 243 Adjusting Tuono V4 1100 Sachs damper The Tuono V4 1100 version is fitted with a non adjustable steering damper No adjustments can be carried out Tuono V4 1100 Factory Ohlins shock absorber ASC The steering damper can be elect...

Page 450: ... screw of the stud bolt to the chassis bottom under the lower yoke Pay attention to the stud bolt collect it when removing the screw Unscrew the fixing screw at the bottom yoke Remove the steering damper TUONO V4 1100 FACTORY ASC Ohlins steering damper After removing the cable glands and the clamp that secure the steering damper wiring harness to it remove the two fixing screws located on the fram...

Page 451: ...2 25 Nm 18 44 lbf ft 4 Lower plate stem fastening screws M8 4 25 Nm 18 44 lbf ft 5 Headstock ring nut tightening M35x1 1 35 5 Nm 25 81 lbf ft Steer repeatedly completely left and completely right to allow the bearings to settle 5 Headstock ring nut tightening check M35x1 1 35 5 Nm 25 81 lbf ft Fit the safety wash er and bend the two opposing tabs into the notches on the lock ring 6 Headstock count...

Page 452: ...f ft Loctite 243 Adjusting play Place the vehicle so that the front wheel is off the ground Carry out a handlebar rotation test using a dynamometer at the hand grip external end The handlebar resistance to rotation must be of 450 250 100 g 0 88 0 55 0 22 lb in both directions Adjust if clearance is detected NOTE THE STEERING COLUMN RESISTANCE TO ROTATION MUST BE PERFORMED IN THE TWO OPPOSITE ROTAT...

Page 453: ...the headstock Loosen the screws fixing the fork stan chions to the upper yoke Remove the upper yoke If necessary remove the wiring har ness fixed in the part below in order to remove the steering plate where re quired Tuono V4 1100 Factory Suspensions SUSP 453 ...

Page 454: ...e loading of the steering bearings by tightening the lower ring nut to the prescribed torque Turn the steering 3 4 times completely from right to left and then check correct tightening torque of such ring nut Place the safety washer bending two opposite tongues inside the ring nut notches Rear Shock absorbers Suspensions Tuono V4 1100 Factory SUSP 454 ...

Page 455: ...EHICLE HAS A HEIGHT ADJUSTABLE SUSPEN SION FOR USE ON THE TRACK PLEASE OBSERVE THE VALUES RECOMMENDED FOR USE ON THE ROAD TO CHANGE THE HEIGHT YOU MUST CONTACT AN Au thorised Aprilia Dealer CAUTION CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PAR TICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE REAR SHOCK ABSORBER STANDARD SETTING IS AD JUST...

Page 456: ... THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES STANDARD ADJUSTMENT FOR ROAD USE Specification Desc Quantity preloaded Spring B length 146 mm 5 75 in Rebound adjustment ring nut 1 open 13 clicks from fully clo...

Page 457: ...PROMISING SHOCK ABSORBER OPERA TION DO NOT LOOSEN THE SCREW 1 AND DO NOT TAMPER WITH THE SEAL UNDERNEATH AS NITROGEN MAY COME OUT RESULTING IN RISK OF ACCIDENTS SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES Operate on the adjusting ring nut 2 as follows to adjust the spring ...

Page 458: ... the RSV4 1100 FACTORY OHLINS ASC ver sion only Unscrew the two screws indicated re trieving the washers and then remove the protective guard of the right hand rider side footpeg Disconnect the brake master pump and move it out of the way laterally Remove the cable clamp fastening screw and free the wiring harness of the damper Disconnect the connector for the elec tronic rebound control Suspensio...

Page 459: ...ing the shock absorber to the dual link The following operations are valid for all ver sions Remove the upper fixing screw of the shock absorber to the frame Slightly lower the shock absorber and rotate it anti clockwise by approx 90 to aid removal Tuono V4 1100 Factory Suspensions SUSP 459 ...

Page 460: ...eep the rear shock absorber unloa ded Then proceed as described SINGLE LINKAGE Working on the right hand side of the vehicle unscrew the nut 1 fastening the single linkage to the frame pulling the screw out from the left hand side to remove it Working on the left hand side of the vehicle unscrew the nut 2 fastening the single linkage to the frame pulling the screw out from the right hand side to r...

Page 461: ...ibed below to remove the components of the single linkage Remove the pins Remove the oil seals Use a press and the specific punch to remove the two roller bearing cages one on each side Specific tooling 020456Y Ø 24 mm adaptor 020376Y Adaptor handle Tuono V4 1100 Factory Suspensions SUSP 461 ...

Page 462: ...O THE CORRECT POSITIONING OF THE PARTS AND CHECK SEV ERAL TIMES THAT JOINTS MOVE SMOOTHLY Checking CAUTION CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED DAMAGED CRACKED AND OR DENTED REPLACE ALL DAMAGED COMPONENTS ROLLER BEARING CAGE Turn the roller bearings by hand The bearings must turn smoothly without impediment or noise No endfloat is permitted Replace any roller bearings with any of the pr...

Page 463: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 464: ...shing M18x1 5 1 12 Nm 8 85 lbf ft 4 RH upper rear regulator bushing M18x1 5 1 12 Nm 8 85 lbf ft 5 RH upper rear coupling M10 1 50 Nm 36 88 lbf ft 6 LH upper rear coupling M10 1 50 Nm 36 88 lbf ft 7 LH upper rear engine coupling fas tening screws M8 3 25 Nm 18 43 lbf ft 8 Saddle mounting fixing screws M10 4 50 Nm 36 88 lbf ft Wheels Chassis Tuono V4 1100 Factory CHAS 464 ...

Page 465: ... nut M25x1 5 1 80 Nm 59 00 lb ft 2 Front brake disc fastening screws M8 6 6 30 Nm 22 13 lb ft Secure using Loc tite 243 or screws that have been pre impregnated with Loctite Removal Support the front part of the motorcycle Remove the front mudguard Tuono V4 1100 Factory Chassis CHAS 465 ...

Page 466: ... fastening nut Retrieve the sealing washer Loosen the screws on the wheel axle clamps Tap the wheel axle slightly with a rub ber mallet so that the hole on the op posite side is exposed Remove the wheel axle by inserting a screwdriver in the holes on the pin Chassis Tuono V4 1100 Factory CHAS 466 ...

Page 467: ...bearings do not fall within the control parameters Replace both wheel bearings CHECKING RADIAL AND AXIAL PLAY Check the radial and axial play Axial play minimal axial play is permitted Radial none If one or both bearings do not fall within the control parameters Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE SEALS Check the con...

Page 468: ... a dial gauge check that the ra dial A and the axial B eccentricities of the rim do not exceed the limit value An excessive eccentricity is usually caused by worn or damaged bearings Replace the rim if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 0 8 mm 0 031 in Rear wheel Chassis Tuono V4 1100 Factory CHAS 468 ...

Page 469: ... 5 30 Nm 22 13 lbf ft Loct 243 Rimozione To proceed with the removal of the rear wheel lift the motorcycle using an appropriate rear stand and proceed as described Undo the fastening nut 1 of the wheel Remove the washer 2 On both sides of the vehicle loosen the lock nut 3 of the adjuster screw 4 and then tighten the adjuster screw to release the tension of the chain ten sioner Tuono V4 1100 Factor...

Page 470: ...om the sprock et and remove the rear wheel 9 REAR SPROCKET SUPPORT REMOVAL Remove the final drive assembly NOTE THE FLEXIBLE COUPLING REMAIN INSTALLED ON THE WHEEL REMOVAL Place the final drive assembly in a vice TO PROTECT THE CROWN GEAR INSTALL PROTEC TIONS ON THE JAWS OF THE VICE IN WOOD OR ALUMI NIUM SECURE ONLY THE CROWN GEAR IN THE VICE DO NOT BLOCK ANY OTHER COMPONENT OF THE FINAL DRIVE ASS...

Page 471: ... attention to the locking screws of the flexible coupling holder which must be perfectly seated If anomalies are noted it is necessary to proceed with the REPLACEMENT of the complete rim WARNING DO NOT REMOVE THE LOCKING SCREWS OF THE FLEXIBLE COUPLING HOLDER OR CHECK THE TIGHTENING TORQUE ANY MAINTENANCE INTERVENTION ON THESE COMPONENTS MAY CAUSE A VEHICLE MAL FUNCTION FITTING Fit the sprocket 3 ...

Page 472: ...UTION IN THIS WAY THE PRESSURE EXERTED BY THE FIXING ELEMENTS WILL BE EVENLY DISTRIBUTED ON THE COUPLING SURFACE Checking CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR REAR WHEEL BEARINGS Check the bearings installed on the wheel CHECKING ROTATION Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noise...

Page 473: ...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 Using a dial gauge check that the ra dial A and the axial eccentricity B of the rim 2 do not exceed the limit val ue An excessive eccentricity is usually caused by worn or damaged bearings Replace the rim 2...

Page 474: ...l play is permitted Radial 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 To check Fit the entire final drive unit 6 to the wheel Manually rotate the sprocket 7 to right and left and check the clearance be tween the flexible couplings 5 an...

Page 475: ...AUTION THE CIRCLIP 11 IS ONLY INSTALLED ON THE RIGHT HAND SIDE OF THE WHEEL There are notches A for engaging with the teeth of the extractor tool at the ends of the spacer 12 Use the extractor tool to remove the right hand bearing 13 Specific tooling AP8140180 Bearing extractor Retrieve the inner spacer 12 On the left hand side of the wheel Use the extractor tool to remove the left hand bearing 16...

Page 476: ...7 IS FITTED ONLY ON THE FINAL DRIVE UNIT LEFT SIDE Remove the left bearing 18 with the specific extractor Collect the inside spacer 19 Remove the right bearing 20 with the specific extractor Retrieve the right hand spacer 21 Clean the inside of the hub thoroughly CAUTION WASH ALL COMPONENTS WITH CLEAN DETERGENT SOLUTION Specific tooling AP8140180 Bearing extractor Chassis Tuono V4 1100 Factory CHA...

Page 477: ...ption Type Quantity Torque Notes 1 Swingarm regulator bushing M30x1 5 1 12 Nm 8 85 lbf ft 2 Swingarm ferrule M30x1 5 1 60 Nm 44 25 lbf ft 3 Swingarm pin nut M20x1 5 1 65 Nm 47 94 lbf ft AGIP GREASE SM2 Tuono V4 1100 Factory Chassis CHAS 477 ...

Page 478: ...the side fairings radiators exhaust silencers centre mani fold shock absorber rear wheel and rear mud guard and the chain guard beforehand secure the front of the vehicle with straps and support the rear with a workshop crane lift Then proceed as described Remove the two cable guides on the inner right hand side of the swingarm Detach the rear brake calliper com plete with mount from the pin on th...

Page 479: ...y shaft freeing if from the final drive chain Remove the nut with the screw fasten ing the dual linkage to the swingarm Working on the left hand side of the vehicle unscrew and remove the fas tener nut of the swingarm pin retriev ing the washer Working on the right hand side of the vehicle loosen the locking ring nut Tuono V4 1100 Factory Chassis CHAS 479 ...

Page 480: ...emove the swingarm completely from the ve hicle from the rear UPON REMOVING THE REAR SWINGARM PAY ATTEN TION NOT TO JAM THE GEARING CHAIN If necessary use a specific tool to re move a pin from the drive chain Open and remove the chain Checking Remove the swingarm Clean the two sides of the bearing seats with a cloth Slide off the bushing 1 Remove the sealing gasket 2 Remove the sealing gasket 3 Re...

Page 481: ...L COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR SWINGARM BEARINGS Carry out the check with the bearings fitted on the swingarm ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control parameters Replace both swingarm bearings RADIAL AND AXIAL CLEARANCE CHECK Check the r...

Page 482: ...justment bush into its seat and tighten by hand CAUTION THE ADJUSTMENT BUSH MUST NOT PROTRUDE BEYOND THE INNER EDGE OF THE FRAME Supporting the front end of the swing arm move it into a position which aligns the holes while simultaneously fitting the pin completely into place Ensure that the hexagonal profile on the head of the pin is engaged correctly in the hexagonal inner seat in the ad justmen...

Page 483: ...Fit the washer on the pin fit the nut and then tighten the nut to the specified tor que Refit the chain onto the drive sprocket and fit the front sprocket complete with chain onto the shaft Fit the screw complete with cup spring washer and T bush Tuono V4 1100 Factory Chassis CHAS 483 ...

Page 484: ...r to remove the front sprocket first slacken the tension of the final drive chain Then proceed as described Remove the three fastener screws 1 of the front sprocket cover 2 retriev ing the spacer 3 Remove the fastener screw 4 of the sprocket complete with the T bush 5 and the cup spring washer 6 Chassis Tuono V4 1100 Factory CHAS 484 ...

Page 485: ...d In this case replace the rear sprocket and the final drive chain also Installing To proceed with the installation of the front sprock et proceed as described Assemble the front sprocket 1 with the drive chain 2 and fit onto the transmission shaft Fit the fastener screw 3 of the front sprocket complete with T bush 4 and cup spring washer 5 and tighten to the specified torque Tuono V4 1100 Factory...

Page 486: ...ent paragraph Drive chain Removing The transmission chain although closed has a different coloured hammerlock where provided which should be used to perform opening disas sembling procedures NOTE WHERE PRESENT THE HAMMERLOCK 1 MAY ALSO BE IDENTIFIED BY A SIGN 2 APPLIED IN THE MOUNTING LINES DURING MANUFACTURING To dismantle and remove the chain proceed as follows Partially remove the pins 3 using ...

Page 487: ... Remove the outer plate 4 Remove the outer O ring rings 5 Remove the inner plate 6 Collect the inner O ring rings 7 and completely remove the transmission chain Tuono V4 1100 Factory Chassis CHAS 487 ...

Page 488: ... stretch of 1 5 3 Chain with chain stretch of 3 which must therefore be replaced in accordance with ap plicable legislation Perform the procedure described as follows to check chain wear Tauten the chain Place the jaws of the tool on the rollers at the opposite ends of a STRAIGHT length of chain consisting of 8 chain links Check that the notch on the sliding jaw matches the correct marking on the ...

Page 489: ...ZE THE CHAIN Check that the links in the transmission chain are not seized and that it can move in both directions Use a generic clincher to re tighten the pins of the link checking riveting at points A Turn the pin of the specific tool 90 and re engage the link pin again checking riveting at points B Grease the chain and record the clearance Tuono V4 1100 Factory Chassis CHAS 489 ...

Page 490: ... on the lower branch of the chain is about 20 mm 0 78 in Move the vehicle forwards to check the vertical deflection of the chain in other positions the chain deflection must be constant throughout the entire rotation of the wheel if the clearance is uniform but greater or less than 20 mm 0 78 in carry out the adjustment CAUTION IF THE CLEARANCE IS GREATER IN SOME POSITIONS IT MEANS THAT SOME ELEME...

Page 491: ...aged rollers loosened pins dry rusty flattened or jammed chain links excessive wear missing sealing rings excessively worn or damaged pinion or sprocket teeth IF THE CHAIN ROLLERS ARE DAMAGED THE PINS ARE LOOSE AND OR THE SEAL RINGS ARE DAMAGED OR MISSING THE ENTIRE CHAIN UNIT PINION SPROCKET AND CHAIN NEEDS TO BE REPLACED LUBRICATE THE CHAIN REGULARLY ESPECIALLY IF THERE ARE DRY OR RUSTY PARTS CR...

Page 492: ...iders Place the vehicle on its OPTIONAL rear service stand Remove the front sprocket cover and check the front shoe 1 and the chain slider shoe 2 for wear or damage Re place if worn or damaged LOWER SHOE In order to remove the lower shoe first slacken the tension of the final drive chain Then remove the indicated spacer and remove the lower shoe In order to remove the chain slider shoe the swingar...

Page 493: ... Remove the lateral screw Remove the upper screw Remove the chain slider shoe Tuono V4 1100 Factory Chassis CHAS 493 ...

Page 494: ...octite 243 For use in countries where it is mandatory to fit the passenger s footrests or for the two seater configu ration 3 Rider s heel guard fastening screws M6 2 2 8 Nm 5 90 lbf ft 4 Passenger s heel guard fastening screws M6 2 2 8 Nm 5 90 lbf ft 5 Anti creep pin M6 1 8 Nm 5 90 lbf ft Rimozione LEFT RIDER FOOTREST REMOVAL GEAR BOX LEVER Remove the fuel tank Loosen the screw 1 and ease off the...

Page 495: ... fixing screw 4 of the ca ble grommet 5 Cut the two clamps 6 that connect the wiring of the quick shift to the wiring of the side stand and of the lambda probe Disconnect the connector 7 of the quick shift and release the wiring Tuono V4 1100 Factory Chassis CHAS 495 ...

Page 496: ...w to change the O rings NOTE NOTE THE WIRING HARNESS DOES NOT NEED TO BE DISCONNECTED FOR THIS OPERATION REMOVING THE RIGHT HAND RIDER FOOT PEG REAR BRAKE PEDAL Remove the two screws fastening the rear brake master cylinder and fasten ing the guard to the footpeg Disconnect the brake master cylinder Chassis Tuono V4 1100 Factory CHAS 496 ...

Page 497: ... FOOTRESTS THE OPERATIONS DESCRIBED BELOW RE FER TO A SINGLE PASSENGER FOOTREST BUT ARE VALID FOR BOTH Remove the seeger ring 1 Extract the pin 2 While pressing the side plates remove the complete pedal 3 Check that the plates 4 are aligned correctly before dismantling the pedal taking care not to lose the spring 5 and the ball 6 Tuono V4 1100 Factory Chassis CHAS 497 ...

Page 498: ...e the footrest support 8 Stand SIDE STAND Pos Description Type Quantity Torque Notes 1 Screws for fastening the stand to the frame M10 2 45 Nm 33 19 lbf ft Loct 243 2 Rotary switch fixing screw M6 1 10 Nm 7 37 lbf ft Loct 243 Chassis Tuono V4 1100 Factory CHAS 498 ...

Page 499: ...described Disconnect the connector 1 of the side stand sensor and remove the ca ble tie 2 to free the wiring harness from the subframe Remove the rubber cable retainer clip 3 and the spiral cable protector 4 to free the wiring harnesses Remove the fastener screw of the met al cable retainer 5 and the cable tie 6 securing the wiring harnesses to the chain guide Free the wiring harness of the side s...

Page 500: ...uts M7 8 13 Nm 9 59 lbf ft 2 Silencer central manifold clamp fas tening screw M6 1 20 Nm 14 75 lbf ft 3 Screw used to secure the silencer to the RH footrest support M8 1 25 Nm 18 44 lbf ft 4 Exhaust valve motor support fixing screw M6 1 8 Nm 5 90 lbf ft 5 Lambda probe fastener M12x1 25 2 25 Nm 18 43 lbf ft 6 Silencer heat shield fixing screws M6 3 8 Nm 5 90 lbf ft 7 Exhaust valve opening closing l...

Page 501: ...and Remove the three fixing screws of the heat guard Remove the heat guard making sure to recover the washers Loosen the clamp between the ex haust terminal and the central mani fold Loosen the adjustment nuts of the ex haust valve Tuono V4 1100 Factory Chassis CHAS 501 ...

Page 502: ...d the spacer Disconnect the actuator cables of the exhaust valve Remove the exhaust terminal com pletely INSTALLATION CAUTION IN CASE OF DISCOLOURATION OF THE SILENCER APPLY FINISHING POLISH WITH A SOFT CLOTH Fit the exhaust silencer onto the centre manifold Chassis Tuono V4 1100 Factory CHAS 502 ...

Page 503: ...able free play adjust ment procedure described in the para graph EXHAUST BUTTERFLY VALVE in the chapter ELECTRICAL SYSTEM Carry out the exhaust valve actuator cable free play adjustment procedure and then tighten the lock nuts of the adjuster screws to the specified torque Tighten the screw of the clamp con necting the exhaust silencer and the centre manifold to the specified torque Tuono V4 1100 ...

Page 504: ... the connector of the rear cylinder bank lambda probe and de tach it from the chain guide Detach the springs and remove the centre exhaust manifold easing it out from underneath Removing the exhaust manifold 2 IN 1 FRONT EXHAUST MANIFOLD In order to remove the exhaust manifolds the side fairings lower fairings and the radiators must be removed beforehand Then proceed as described Release the sprin...

Page 505: ...nder bank exhaust head ers in addition to the components described pre viously for removal of the front cylinder bank exhaust headers it is also necessary to remove the centre catalytic converter Then follow the steps for removal described below Remove the left hand rider footpeg mount Remove the screw fastening the en gine mount to the frame and the three screws fastening the mount to the en gine...

Page 506: ...ed correctly see the paragraph EX HAUST VALVE in the chapter ELECTRICAL SYSTEM See also Butterfly valve in exhaust Engine oil cooler OIL RADIATOR pos Description Type Quantity Torque Notes 1 Screws fastening oil radiator to mounting bracket M6 1 7 Nm 5 16 lb ft 2 Screws fastening oil radiator mount ing bracket to engine M6 2 8 Nm 5 90 lb ft Chassis Tuono V4 1100 Factory CHAS 506 ...

Page 507: ...iator pipe Release the clamp and disconnect the left hand radiator pipe Remove the split pin From the opposite site remove the coolant radiator oil radiator connector pin Unscrew and remove the lower radia tor retainer Remove the radiator draining com pletely of oil See also Replacement Tuono V4 1100 Factory Chassis CHAS 507 ...

Page 508: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 509: ...OL UNIT Pos Description Type Quantity Torque Notes 1 Oil tube screws M10x1 4 23 26 Nm 16 96 19 18 lbf ft 2 Control unit support screws M6 2 6 8 1 Nm 5 01 0 74 lbf ft Tuono V4 1100 Factory Braking system BRAK SYS 509 ...

Page 510: ...Operating diagram ABS functional diagram key Braking system Tuono V4 1100 Factory BRAK SYS 510 ...

Page 511: ...t brake master cylinder 4 Outlet to front brake calliper ABS OPERATION General specifications The front circuit is similar to the rear circuit The ABS inlet valve 10 11 is normally open and it is closed only when the system inter venes to avoid wheel locking The exhaust valve 12 14 is normally closed and is only opened when the system inter venes to prevent locking With the system in stand by mode...

Page 512: ...M DESCRIPTION The ABS system is a device to avoid wheels locking in case of emergency braking increasing vehicle braking stability when compared to a traditional braking system The ABS system improves vehicle control provided that the physical limits of vehicle grip on the road are not exceeded The rider is fully responsible for riding at a suitable speed based on weather and road conditions alway...

Page 513: ...n active ABS system During the vehicle start up after the in strument panel initial check the ABS warning light stops flashing when the speed is under 5 km h 3 1 mph If the ABS warning light remains on when the vehicle is running it means that a fault has been detected and the ABS system has been automatically deactivated IN CASE OF FAILURE OR WITH ABS DISCONNECTED THE VEHICLE OPERATES AS IF IT DI...

Page 514: ...acement or refitting of the front brake lines take care that the steel ends are correctly lodged in the respective seats on the radiator sup port Use clamps to secure any axial move ments of the hoses Reposition the front brake steel pipes in the conduit secure the pipes using clamps and observing the tolerances indicated in the figure Characteristic Pipe axial clearance 0 0 10 mm 0 0 39 in Brakin...

Page 515: ...he diagnostics instrument on the ABS control unit and on the 7SM one Before returning the vehicle carry out a functional road test REPLACING ACTIVATING NEW ABS CONTROL UNIT In case of replacement of the ABS control unit ensure that the new one has caps on all four hydraulic connections and then proceed as follows Before disconnecting the electrical connections switch the key OFF After hydraulic an...

Page 516: ...ide 3 Cable grommet 4 Cable grommet TABLE C ABS PIPES ROUTING The hydraulic pipes must necessarily pass as shown in the figure TABLE D ABS PIPES ROUTING 1 Delivery rear calliper 2 Input from the rear pump 3 Delivery front calliper 4 Input from the front pump 5 Medium clamp Braking system Tuono V4 1100 Factory BRAK SYS 516 ...

Page 517: ...perfectly operative as any other braking system without ABS The detection of malfunctions may require more or less time according to the type of failure Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time If during this given time one of the conditions is missing but then it comes back the timer is reset and the system is no lo...

Page 518: ...trument panel malfunction Use of diagnostics instrument for ABS system Abs screen pages ECU INFO screen page This screen shows general data regarding the con trol unit for example software type mapping con trol unit programming date CONTROL UNIT DATA P A D S characteristic Value example Units of measure ment Notes Spare part code CM281701 SW version Vehicle manuf or encoding Chassis or diagn tool ...

Page 519: ...km h Speed of the rear wheel km h Battery voltage D Front brake circuit pressure bar ABS Quality test of the sensors When turning the wheel or acting on the brake a variation of parameters must be detected ACTIVATION screen page On this screen you can delete the errors from the memory of the controller and you can enable some systems controlled by the control unit ACTIVATIONS P A D S characteristi...

Page 520: ... electric valve relay Internal error fault at the control unit C1021 fault at the control unit Low power supply voltage C1058 low voltage High power supply voltage C1059 high voltage Encoding error C1089 CAN error controller error U2921 controller error CAN error line failure busoff U2922 line failure busoff CAN error failed reception at the instrument panel U2924 failed reception at the instrumen...

Page 521: ...nostic tool in order to generate an errors report When started the program select the brand Select the vehicle and the component Select Self diagnosis Go to the page Error codes Select an error and show the Ambient parameter error where provided Tuono V4 1100 Factory Braking system BRAK SYS 521 ...

Page 522: ...then on Print and select the virtual PDF printer If there is no PDF printer there are several free programs ask the infor mation systems to install it Name the file with a name that contains the main information of the vehicle and the analysed component e g CN1200 Chassis0465 Instrument panel Braking system Tuono V4 1100 Factory BRAK SYS 522 ...

Page 523: ...Check the type and dimensions of the installed tyres Check the type and dimensions of the installed tone wheels C1031 Rear wheel speed sensor Electrical diagnosis Open circuit short circuit to negative or short circuit to positive Error cause Open circuit circuit interruption detected Short circuit to negative null voltage detected on PIN 14 of the ABS control unit Short circuit to positive excess...

Page 524: ...eel is correct Check that the tone wheel and the sensor are correctly positioned Check that the tyre is the correct size If all these checks are positive replace the sensor C1033 Front wheel speed sensor Electrical diagnosis Open circuit short circuit to negative or short circuit to positive Error cause Open circuit circuit interruption detected Short circuit to negative null voltage detected on P...

Page 525: ...l these checks are positive replace the sensor VOLTAGE ERRORS C1058 Low power supply voltage C1059 High power supply voltage Error cause Power supply voltage below minimum threshold or above maximum threshold detected on PIN 4 or on PIN 18 of the ABS control unit This error is indicated by lighting up in a fixed manner the ABS warning light Troubleshooting Check that the voltage regulator is worki...

Page 526: ...ntinuity of wiring harness between PIN 2 of the ABS control unit and PIN 33 of the instrument panel Orange cable between PIN 11 of the ABS control unit and PIN 32 of the instrument panel White Black cable U2925 Failed reception from injection control unit Error cause Communication problem with the injection control unit possible CAN line contact Troubleshooting Check continuity of wiring harness b...

Page 527: ...ton open the button must be closed with the button closed the button must be open Modulator REMOVING THE ABS MODULATOR To remove the ABS modulator first drain the brake system and then follow the procedure described below Disconnect the connector from the ABS control unit Remove the cable tie fastening the ABS pipes to the metal plate Unscrew and remove the screws fas tening the ABS pipes to the m...

Page 528: ...nt to the frame Partially free the ABS modulator mount from the rubber bush Remove the ABS modulator complete with mount from the vehicle Remove the two screws fastening the ABS modulator to the mount Braking system Tuono V4 1100 Factory BRAK SYS 528 ...

Page 529: ...late pre fit a cable tie onto the plate This cable tie will be used later to fasten the brake pipes to the metal plate it self ABS CONTROL UNIT CONNECTOR INSERTION PROCEDURE Check the initial position of the connection clip lever When the connector is fully inserted the distance between the connector and the ABS control unit must be 7 5 mm 0 29 in Tuono V4 1100 Factory Braking system BRAK SYS 529 ...

Page 530: ...k periodically and each time the wheels are refitted the tone wheel 2 or the sensor 1 re placed that the wheel distance is constant at each 360 Use a thickness gauge to check the distance between sensor 1 and tone wheel 2 at three points at a 120 span The values should be be tween CAUTION IF A VALUE BEYOND THE TOLERANCE RANGE IS MEAS URED REPLACE THE SENSOR 1 AND OR THE TONE WHEEL 2 AND REPEAT THE...

Page 531: ...w and remove the screw and remove the tone wheel sensor 1 CAUTION BEFORE REFITTING MAKE SURE THAT THE FACING SURFACES BETWEEN THE SENSOR 1 AND THE SEAT ITSELF DO NOT SHOW SIGNS OF DAMAGE AND ARE COMPLETELY CLEAN ALWAYS CHECK THE DISTANCE BETWEEN THE SENSOR 1 AND THE TONE WHEEL 2 Rear brake calliper REAR BRAKE CALLIPER Pos Description Type Quantity Torque Notes 1 ABS sensor fixing screw M5x15 1 8 N...

Page 532: ...nipple Using a container of suitable capacity to collect the oil connect a tube to the bleed nipple and unscrew the nipple to drain the system Protect the brake calliper adequately remove the fastener screws of the pipe and plug the pipe Remove the two fastener screws of the brake calliper Braking system Tuono V4 1100 Factory BRAK SYS 532 ...

Page 533: ...o fastener screws of the brake calliper and tighten to the specified tor que Protect the brake calliper adequately connect the brake pipe fit the special screw and then tighten the screw to the specified torque Fill with oil and bleed the system Check the correct functioning of the braking system Tuono V4 1100 Factory Braking system BRAK SYS 533 ...

Page 534: ...lbf ft Removal NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH To remove the front brake calliper it is necessary to previously drain the braking system Remove the protective cap of the bleed nipple and free the wiring harness of the front ABS sensor if applicable Braking system Tuono V4 1100 Factory BRAK SYS 534 ...

Page 535: ...nscrew the nipple to drain the system Remove the fastener screw of the pipe and plug the pipe Remove the two fastener screws of the brake calliper Remove the brake calliper retrieving the two spacers Installing NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH Tuono V4 1100 Factory Braking system BRAK SYS 535 ...

Page 536: ...o fastener screws of the brake calliper and tighten to the specified tor que Protect the brake calliper adequately connect the brake pipe fit the special screw and then tighten the screw to the specified torque Fill with oil and bleed the system Rear brake disc Braking system Tuono V4 1100 Factory BRAK SYS 536 ...

Page 537: ...g the rear wheel Disc Inspection The operations must be carried out with the brake disc fitted on the wheel Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the minimum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 5 mm 0 18 in Using a dial gauge check that the max imum...

Page 538: ...HE SCREWS 1 MAN UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE A B C D E F See also Removing the front wheel Disc Inspection The following operations must be car ried out with the brake discs fitted on the wheel they refer to a single disc but are valid for both Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum th...

Page 539: ... ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE STABILITY AND SAFETY POSING SERIOUS DANGER FOR PEOPLE OBJECTS AND THE VE HICLE ITSELF CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE CALLIPER BUT APPLY TO BOTH Unscrew and remove the two screws 1 Slide off the disc from the front brake calliper Separate the brake calliper pistons Remove the pads from the brake cal liper Retrieve the clip DO N...

Page 540: ...er on the disc Hand tighten the two screws 1 fully Pull the front brake lever to seat the brake calliper correctly Tighten the two screws 1 Check the front brake fluid level Rear brake pads Removal To remove the rear brake pads follow the proce dure described below Remove the two screws 1 fastening the brake calliper to the mount CAUTION DO NOT OPERATE THE REAR BRAKE PEDAL ONCE THE CALLIPER HAS BE...

Page 541: ...E BRAKE LEVER ONCE THE BRAKE PADS HAVE BEEN REMOVED AS THIS MAY FORCE THE PISTONS OUT FROM THEIR SEATS AND ALLOW BRAKE FLUID TO ESCAPE If worn replace the anti vibration plates Installing Insert two new pads and the vibration damping plates placing them so that the holes are aligned with the calliper holes UPON REFITTING MAKE SURE THE ARROWS ON THE VI BRATION DAMPING PLATES FACE THE DIRECTION OF R...

Page 542: ...RECTLY POSITIONED INSIDE THE CALLIPER Fit the safety retainer clip 4 as shown While pressing the centre of the safety retainer clip 4 fit the pin 3 so that it passes over the clip Fit the retainer ring 2 Braking system Tuono V4 1100 Factory BRAK SYS 542 ...

Page 543: ...IRCUIT IS AIR PURGED NOTE THE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY BUT ARE VALID FOR BOTH THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover of the bleed valve Insert the t...

Page 544: ...r still feels spongy after completing all checks it is necessary to bleed the brakes using this type of procedure With the diagnostic tool properly connected select the function FRONT BLEEDING in the section SETTINGS The pump starts running While the pump is performing a rotation cycle operate and release the front brake lever until the message diagnostic tool cycle completion is received This pro...

Page 545: ...and quickly press and re lease the rear brake pedal then keep it fully pressed Loosen the bleed valve by a 1 4 turn so that the brake fluid flows into the con tainer this will release the tension on the brake pedal and it will make it arrive at the end stop Close the bleed valve before arriving at the end of the stroke with the pedal Repeat the operation until the are no air bubbles in the fluid g...

Page 546: ...d accumulate Once the procedure with diagnostic tool is finished perform again the REGULAR PURGING to remove the air from the system completely Front brake pump FRONT BRAKE MASTER CYLINDER Pos Description Type Quantity Torque Notes 1 Screw fastening front brake fluid res ervoir to bracket M6 1 7 Nm 5 16 lbf ft 2 Screw fastening brake fluid reservoir mounting bracket to handlebar M6 1 7 Nm 5 16 lbf...

Page 547: ...tening screws M6 2 8 Nm 5 90 lbf ft Loctite 243 3 Rear brake lever fixing pin M8 1 25 Nm 18 44 lbf ft Loctite 243 4 Tank filler cap 1 17 23 Nm 12 54 16 96 lbf ft 5 Brake lever ferrule fastening screw M6 1 8 Nm 5 90 lbf ft 6 Special oil pipe coupling retaining screw 1 23 26 Nm 16 96 19 18 lbf ft Tuono V4 1100 Factory Braking system BRAK SYS 547 ...

Page 548: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 549: ...YSTEM TYPE Self bleeding cooling circuit with aspirating centrifugal pump 1 three way thermostat valve 2 cooling radiator 3 with electric fans 4 and expansion tank 5 Key Tuono V4 1100 Factory Cooling system COOL SYS 549 ...

Page 550: ...asten ing the water radiator support brack et to the frame M6x20 2 10 Nm 7 38 lbf ft 2 Flanged hex head screws for fasten ing the water radiator to the support bracket M6x20 2 7 Nm 5 16 lbf ft 3 Screws for fastening the water by pass pipe tube gland M5 1 6 Nm 4 43 lbf ft 4 Screws for fastening the electric fans to the water radiator M4 6 0 5 Nm 0 37 lbf ft 5 Screw for fastening the expansion tank ...

Page 551: ...head hex socket screws for fastening the pump to the crank case M6x25 2 10 Nm 7 38 lbf ft Electric fan Remove the front underfairings and the hand grip position sensor Disconnect the cooling fan connector to be replaced Tuono V4 1100 Factory Cooling system COOL SYS 551 ...

Page 552: ...c fan are not the same as the hole 2 com pared to the holes 1 has a different thickness and is therefore fixed from the internal side using a threaded T bushing Now it is possible to remove the electric fan Coolant replacement Remove both fairings Place a container with a suitable ca pacity under the coolant pump Remove the radiator cap valve to help the fluid drain out Cooling system Tuono V4 110...

Page 553: ...sary to reach the edge Fit the cap valve Via the filler orifice on the expansion tank fill with the quantity of coolant necessary to reach the FULL marking then refit the cap Start the engine run at idle speed and wait for the electric fans to activate ap prox 101 C 213 F then turn off the engine and wait for it to cool With the vehicle standing vertically check the liquid level both in the radia ...

Page 554: ...WITH TANK Drain the coolant Remove the pipe from the radiator Unscrew and remove the two screws fastening the pipe to the engine Retrieve the gasket and replace with a new component when refitting Drain two litres of oil from the engine block Unscrew and remove the two screws fastening the pump to the engine Remove the coolant pump Cooling system Tuono V4 1100 Factory COOL SYS 554 ...

Page 555: ... remove the inner screw Remove the pump cover TO PREVENT IRREPARABLE DAMAGE TO THE PUMP UNSCREW AND REMOVE THE INNER SCREW BEFORE REMOVING THE COVER At each removal replace the inner gas ket between the pump casing and the cover and the O ring on the pump cas ing ENSURE THAT THE LIQUID PASSAGE ORIFICES ARE NOT OBSTRUCTED Tuono V4 1100 Factory Cooling system COOL SYS 555 ...

Page 556: ...very tank Tighten by the two flanged M6 nuts on the TCEI M 6x35 screws already fitted taking care not to undo the screws previously tightened Refit the pump Removing the radiator In order to carry out the procedure described below the side fairings the inner side fairings the lower fairings and the chin fairing must be removed beforehand Then proceed as described RADIATOR BRACKET REMOVAL Working o...

Page 557: ...the radiator retainer bracket Moving the bracket outwards it is then possible to remove it by sliding it out CAUTION DURING THE REFIT PHASE MAKE SURE THAT THE MAIN CABLE HARNESS IS CORRECTLY POSITIONED ON THE CAVITY OF THE RADIATOR RETAINER BRACKET IN ORDER TO PRE VENT THE CABLE HARNESS FROM COMING INTO CONTACT WITH THE RADIATOR AT HIGH TEMPERATURE AND DAMAGING ITSELF RADIATOR REMOVAL Tuono V4 110...

Page 558: ...ctric fan Disconnect the mount of the exhaust valve actuator motor from the frame Detach the connector of the left hand electric fan from the mount and discon nect it Detach the expansion tank water drain pipe from the pipe guide connected to the mounting bracket of the radiators and remove the pipe retainer clip se curing the drain pipe to the cable of the demand sensor Remove the cable tie faste...

Page 559: ... valve Move the metal clip along the pipe and disconnect the cooling system pipe from the radiator Remove the cable tie indicated and free the wiring harnesses from the ra diator mount Remove the safety retainer circlip and remove the pin fastening the coolant radiator to the oil radiator Tuono V4 1100 Factory Cooling system COOL SYS 559 ...

Page 560: ...ws fastening the radiator to the mount Separate the water radiator from the mount on the left hand side and re move the radiator while simultaneously removing the expansion tank on the right hand side Cooling system Tuono V4 1100 Factory COOL SYS 560 ...

Page 561: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 562: ... tail fairing pas senger seat TAIL FAIRING INSTALLATION Place the tail fairing by aligning the two hooks A and B with their seats A and B on the vehicle Press the tail fairing downward with one hand and with the other push it backward until it is completely coupled Bodywork Tuono V4 1100 Factory BODYW 562 ...

Page 563: ...THE PASSENGER SEAT IS FITTED ON THE VEHICLE MAKE SURE IT IS PROPERLY FIXED BEFORE ALLOWING THE PASSENGER TO SIT ON IT THE TAIL FAIRING CAN BE USED INSTEAD OF THE PASSENGER SEAT HOWEVER WITH THE TAIL FAIRING IN PLACE PASSENGERS SHOULD NOT BE TRANSPORTED PASSENGER TRANSPORT ON THE TAIL FAIRING IS ILLEGAL AND IT IS EXTREMELY LIKELY THAT THE PASSENGER WILL FALL FROM THE VEHICLE TUONO V4 1100 PASSENGER...

Page 564: ...d dle support passenger handle PASSENGER SADDLE INSTALLATION Place the tail fairing by aligning the two hooks D and E with their seats D and E on the vehicle and push it back ward Press the saddle downward with one hand and then press the external parts to completely engage the pins The operations described below are identical for both versions Bodywork Tuono V4 1100 Factory BODYW 564 ...

Page 565: ...tting and fixing the saddle place the hexagonal wrench in the cor responding seat of the tail fairing pas senger seat Driving mirrors The following procedure is for a single rear view mirror but is applicable to both mirrors Remove the protection sliding it up wards Unscrew the fixing nut holding the low er lock nut ensure that the mirror does not fall Remove the rear view mirror Tuono V4 1100 Fac...

Page 566: ... screws of the instrument panel brow and remove the brow Move the instrument panel to the left forward direction as much as needed to allow the removal of the central rub ber gasket from the slotted hole Disconnect the connector from the in strument panel Unscrew the three screws Remove the washers and the rubber blocks Bodywork Tuono V4 1100 Factory BODYW 566 ...

Page 567: ...adlight unit to the instrument panel support Move the top fairing complete with headlight unit out of the way by just enough to reach and disconnect the connector Remove the eight screws fastening the headlight unit to the front fairing Separate the front fairing from the headlight unit After reassembling check that the headlight beams are aimed correctly Tuono V4 1100 Factory Bodywork BODYW 567 ...

Page 568: ...fairing 2 and remove it Front wheelhouse REMOVING LOWER STEERING YOKE TRIM ELEMENT To remove the lower trim piece of the steering yoke remove the two lateral fastener screws and the relative T bushes Detach the rubber pipe grommet of the brake pipe from the lower trim piece of the steering yoke Bodywork Tuono V4 1100 Factory BODYW 568 ...

Page 569: ...ring yoke Taillight assy Carry out the tail fairing removal pro cedure Unscrew and remove the two lateral screws Undo and remove the upper screw Disconnect the connector and remove the tail light unit Tuono V4 1100 Factory Bodywork BODYW 569 ...

Page 570: ...e the two fixing screws 4 and extract the license plate light 5 by re moving the wiring harness from the li cense plate holder Side body panels To remove the side fairings remove the rider sad dle and then follow the procedure described be low THE PROCEDURE DESCRIBED AS FOLLOWS IS FOR ONE SIDE FAIRING BUT APPLIES TO BOTH Unscrew and remove the lateral screws Bodywork Tuono V4 1100 Factory BODYW 57...

Page 571: ...ing to wards the rear of the vehicle to detach and remove it Side fairings The procedure described below is for one side of the vehicle but is valid for both sides To remove the side fairings proceed as described Remove the three inner clips 1 Remove the upper screw 2 Tuono V4 1100 Factory Bodywork BODYW 571 ...

Page 572: ...release the three inner hooking points To remove the side fairings follow the procedure described below Remove the four screws that fasten the outer part to the inner part Separate the inner part 4 from the outer part 5 Bodywork Tuono V4 1100 Factory BODYW 572 ...

Page 573: ... lock is correctly coupled Fairing mounting panels To remove the under fairings the front fairings the front lock and the side fairings must first be re moved Then proceed as described LEFT HAND UNDER FAIRING Remove the clamp 1 that locks the voltage regulator s wiring harnesses Remove the outer screw 2 and the relative nut fastening the under fairing to the duct Tuono V4 1100 Factory Bodywork BOD...

Page 574: ...olant radiator mount Disconnect the connectors 4 of the voltage regulator Remove the left hand under fairing 5 RIGHT HAND UNDER FAIRING Remove the screw 1 and the relative nut that fastens the side under fairing to the duct Bodywork Tuono V4 1100 Factory BODYW 574 ...

Page 575: ...fairing to the coolant radiator mount Remove the right hand under fairing 4 CENTRAL UNDERFAIRING To remove the central under fairing it is necessary to remove the side fairings Then proceed as de scribed Loosen the four screws fastening the headlight unit to the instrument panel mount Tuono V4 1100 Factory Bodywork BODYW 575 ...

Page 576: ...tral under fairing To refit the under fairings carry out the procedure described previously for removal in re verse order License plate holder To remove the license plate holder follow the pro cedure described below Undo and remove the screw inside of the point indicated in the figure Bodywork Tuono V4 1100 Factory BODYW 576 ...

Page 577: ... To remove the rear mudguard follow the proce dure described below Unscrew and remove the two screws 1 fastening the rear mudguard to the chain guard and the two screws 2 fastening the mudguard to the swing arm Remove the mudguard easing it out towards the rear of the motorcycle Tuono V4 1100 Factory Bodywork BODYW 577 ...

Page 578: ...elow Remove the front fixing screws On both sides of the vehicle remove the side fixing screws Remove the lower fairings To remove the lower fairings follow the procedure described below Remove the side screws Remove the lower screws Bodywork Tuono V4 1100 Factory BODYW 578 ...

Page 579: ...of the lower fairings Separate the two lower fairings Fuel tank In order to remove the fuel tank the rider saddle and side covers must be removed beforehand Then proceed as described Remove the front screw 1 fastening the tank to the frame Tuono V4 1100 Factory Bodywork BODYW 579 ...

Page 580: ...e tank to the saddle carrier subframe Uncouple from its support the connec tor 3 of the fuel pump and disconnect it Disconnect the connector 4 of the in ertia platform Disconnect the two breather pipes 5 Bodywork Tuono V4 1100 Factory BODYW 580 ...

Page 581: ...y and disconnect the fuel pipe 6 Remove the fuel tank 7 To remove the fuel filler follow the procedure de scribed below Remove the four fastener screws 8 of the filler Remove the cap 9 Tuono V4 1100 Factory Bodywork BODYW 581 ...

Page 582: ...heelhouse To remove the rear wheel splash guard first re move the battery the fuel tank the saddles the grab handle the bodywork parts constituting the tail fairing the license plate holder the side covers and the passenger footpeg mounts Then proceed as described Disconnect the main injection relay holder from the mount 1 Bodywork Tuono V4 1100 Factory BODYW 582 ...

Page 583: ...g har ness 3 from the cable retainer clips on the splash guard Detach the connector 4 for connect ing the diagnostic tool from the mount on the splash guard Detach the connector 5 of the side stand sensor from the mount on the splash guard Tuono V4 1100 Factory Bodywork BODYW 583 ...

Page 584: ...he metal plate to the mount Partially free the ABS modulator mount from the rubber bush Remove the two screws 9 fastening the rear wheel splash guard to the sad dle carrier subframe Ease out the splash guard 10 towards the rear of the vehicle to remove it Bodywork Tuono V4 1100 Factory BODYW 584 ...

Page 585: ...e mudguard Detach the rubber clip fastening the brake pipe On both sides of the vehicle remove the fastener screws of the mudguard Unscrew the nuts situated on the inner side of the mudguard to remove the re flectors CAUTION WHEN REASSEMBLING MAKE SURE THAT THE PIN ON THE LEFT HAND REFLECTOR IS INSERTED CORRECTLY INTO THE RESPECTIVE HOLE IN THE MUDGUARD Tuono V4 1100 Factory Bodywork BODYW 585 ...

Page 586: ... Then proceed as described Unscrew and remove the three screws 1 and remove the passenger handle 2 Instrument cluster cover To remove the instrument panel cover after removing the top ring remove the two fixing screws of the instrument panel cover Remove the instrument panel cover Bodywork Tuono V4 1100 Factory BODYW 586 ...

Page 587: ...eadlight unit the instrument panel cover and the instrument panel Then proceed as described Working from both sides of the vehicle remove the two screws 1 Remove the two upper fixing screws 2 Remove the top fairing support 3 Remove the five screws 4 that fasten together the two instrument panel sup ports Tuono V4 1100 Factory Bodywork BODYW 587 ...

Page 588: ... Remove the two screws 5 that fasten the left side instrument panel support to the chassis Remove the left instrument panel sup port 6 Remove the two clamps 7 Bodywork Tuono V4 1100 Factory BODYW 588 ...

Page 589: ... wiring har nesses Remove the two screws 9 that fasten the right side instrument panel support to the chassis Remove the right instrument cluster support Battery Ensure that the ignition switch is turned to OFF Remove the rider saddle Remove the two screws 1 Tuono V4 1100 Factory Bodywork BODYW 589 ...

Page 590: ...Refit the rider saddle CHECK THAT THE CABLE TERMINALS AND BATTERY LEADS ARE IN GOOD CONDITION NOT CORRODED OR COVERED BY DEPOSITS COVERED BY NEUTRAL GREASE OR PETROLEUM JELLY CAUTION UPON REFITTING CONNECT THE LEAD TO THE POSITIVE TERMINAL FIRST AND AFTER WARDS THE LEAD TO THE NEGATIVE TERMINAL If the saddle had been refitted remove it Install the battery 6 in its seat Position the positive cable ...

Page 591: ...E NOTE IN ORDER TO INSTALL AND USE A NEW CONVENTIONAL LEAD BATTERY THE SPACER 7 INSTALLED ON THE SECONDARY FUSE HOLDER MUST BE REMOVED ACT ON THE LOCKING TABS 8 TO REMOVE THE SPACER 7 Tail guard In order to remove the tail fairing the saddles and the side covers must be removed beforehand Then proceed as described TUONO V4 1100 After having unscrewed and removed the three screws 1 remove the pas s...

Page 592: ...the upper fastener screws 3 Remove the lateral fastener screw 4 Unscrew the two rear fastener screws of the tank by just enough to allow the tank to be lifted slightly in order to de tach the front part of the right hand tail fairing section and remove the tail fair ing section completely Bodywork Tuono V4 1100 Factory BODYW 592 ...

Page 593: ...air deflectors To proceed with the removal of the side ducts it is necessary to remove the front fairing together with the headlight unit and then proceed as described The following operations refer to a single duct but apply to both ONLY FOR THE TUONO V4 1100 VERSION Remove the upper screw Remove the lateral screw Remove the deflector Tuono V4 1100 Factory Bodywork BODYW 593 ...

Page 594: ...screw and the relative nut fixing the duct to the under fairing Operating through the hole on the side of the duct unscrew and remove the internal screw Unscrew and remove the external screw Remove the duct Bodywork Tuono V4 1100 Factory BODYW 594 ...

Page 595: ...0 226 304 324 327 329 333 335 340 Coil 208 Connecting rods 387 391 400 Connectors 250 coolant 552 Coolant 552 Countershaft 380 382 385 390 Crankcase 378 386 390 402 Crankshaft 388 390 399 Cylinder 83 89 D Desmodromic drum 309 Diagnostics 518 Drive chain 19 486 E ECU 251 518 Electric fan 230 551 Electrical system 7 19 104 106 Engine oil 70 506 Engine temperature sensor 189 Exhaust 234 500 504 506 E...

Page 596: ... Maintenance 14 64 157 530 Mirrors 565 Mudguard 577 585 O Oil filter 73 Oil pressure sensor 224 Oil sump 385 411 One way valve 414 P Pistons 387 391 400 Primary shaft 308 R Radiator 556 Rear cylinder head valves 89 Rear head 359 365 367 373 385 388 Rear wheel 468 537 Recommended products 67 Ride by wire 421 Run Stop switch 233 S Saddle SAS valve actuator 231 Scheduled maintenance 64 Secondary air ...

Page 597: ... 228 Spark plug 68 Speed sensor 176 Stand 228 498 499 Start up 161 316 Starter motor 315 Steering damper 448 Stepper motor 424 T Tank 579 Throttle body 211 422 423 Track Transmission 18 384 385 Tyres 21 U Use 518 W Water pump 385 407 554 Wiring diagram 149 ...

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