APRILIA RSV 1000 TUONO R Manual Download Page 111

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use and maintenance

RSV 1000 TUONO R

111

GEAR RATIOS

Ratio

Primary

Secondary

1st

31/60 = 1 : 1.935 15/34 = 1 : 2.267

2nd

19/31 = 1 : 1.632

3rd

20/26 = 1 : 1.300

4th

22/24 = 1 : 1.091

5th

25/24 = 1 : 0.960

6th

26/23 = 1 : 0.885

Final ratio

Total ratio

16/40 = 1: 2.500

1:10.986
1: 7.895
1: 6.290
1: 5.279
1: 4.645
1: 4.280

DRIVE CHAIN

Type...................................................................

endless (with no connection link) with sealed links

Model ................................................................

525

FUEL SUPPLY
SYSTEM

Type...................................................................

electronic injection (Multipoint)

Throttle ..............................................................

Ø 57 mm

FUEL SUPPLY

Fuel ...................................................................

premium-grade unleaded petrol, minimum octane rating 95 (ROM) and
85 (MON).

FRAME

Type...................................................................

double beam, inclined in aluminium alloy, box-type.

Steering head angle ..........................................

25°

Trail....................................................................

101.7 mm (with tyre 120/70)

SUSPENSIONS

Front ..................................................................

adjustable hydraulic upside-down fork, Ø 43 mm

Stroke................................................................

120 mm

Rear ..................................................................

aluminium alloy double-sided swinging arm with progressive linkage and
APS system. Adjustable hydraulic shock absorber in rebound and
compression damping

Wheel travel ......................................................

133 mm

BRAKES

Front ..................................................................

twin floating disc - Ø 320 mm, four-piston callipers - Ø 34 mm

Rear ..................................................................

Disc brake - Ø 220 mm, twin-piston calliper - Ø 32 mm

WHEEL RIMS

Type...................................................................

light alloy, removable shaft

Front ..................................................................

3.50 x 17"

Rear ..................................................................

6.00 x 17"

APRum_TUONO_MY05_01_UK.book Page 111 Monday, September 26, 2005 5:15 PM

Summary of Contents for RSV 1000 TUONO R

Page 1: ...8104928 RSV 1000 TUONO R APRum_TUONO_MY05_01_UK book Page 1 Monday September 26 2005 5 15 PM ...

Page 2: ...RMATION The operations preceded by this symbol must be repeated also on the opposite side of the vehicle If not expressly indicated otherwise for the reassembly of the units repeat the disassembly operations in reverse order The terms right and left are referred to the rider seated on the vehicle in the normal riding position If the glove tool kit compartment cover has been installed as an alterna...

Page 3: ...rce require periodical inspections The user of the vehicle in these countries must contact an aprilia Authorised Dealer to have the non homologated components replaced with others homologated for use in the country in question carry out the required periodical inspections NOTE Soon after purchasing the vehicle write down the identification data indicated on the SPARE PARTS IDENTIFICATION LABEL in ...

Page 4: ...ON DATA 61 JOINTS WITH CLICK CLAMPS AND WITH SCREW CLAMPS 61 CHECKING AND TOPPING UP ENGINE OIL LEVEL 62 CHANGING ENGINE OIL AND THE ENGINE OIL FILTER 63 AIR FILTER 66 FITTING THE PINS FOR THE REAR WHEEL STAND 67 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND 67 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND 68 FRONT WHEEL 68 FRONT BRAKE CALLIPERS 71 REAR WHEEL 72 DRIVE CHAIN 75 REMOVING TH...

Page 5: ...safe drive APRum_TUONO_MY05_01_UK book Page 5 Monday September 26 2005 5 15 PM ...

Page 6: ...rider s lack of experience NEVER lend the vehicle to beginners and in any case make sure that the rider has all the requirements for driving Rigourously observe all road signs and national and local road regulations Avoid abrupt movements that can be dangerous for yourself and other people for example wheeling speeding etc and give due consideration to the road surface visibility and other driving...

Page 7: ...lways remember to report any malfunction to the technicians to help them in their work Never use the vehicle when the amount of damage it has suffered endangers your safety Never change the position inclination or colour of number plate direction indicators lights and horns Any modification of the vehicle will result in the invalidity of the guarantee Any modification of the vehicle and or the rem...

Page 8: ... case of fall for example pointed objects like keys pens glass vials etc in your pockets the same recommendations also apply to a possible passenger ACCESSORIES The owner of the vehicle is responsible for the choice installation and use of any accessory Avoid installing accessories that cover horns or lights or that could impair their functions limit the suspension stroke and the steering angle ha...

Page 9: ...rips Avoid hanging bulky heavy and or dangerous objects on the handlebars mudguards and forks because the vehicle might respond more slowly in turns and its manoeuvrability could be unavoidably impaired Do not place bags that are too bulky on the vehicle sides and do not ride with the crash helmet hanging on one side because they could hit people or obstacles making you lose control of the vehicle...

Page 10: ...ft side body panel 9 Rider seat 10 Battery 11 Main fuse carrier 30A 12 Passenger seat glove tool kit compartment lock 13 Passenger left footrest snapping closed open 14 Drive chain 15 Swinging arm 16 Rider left footrest 17 Side stand 18 Gear shift lever 19 Engine oil filter 20 Engine oil tank 21 Engine oil level 1 4 3 2 21 20 5 6 7 8 9 10 11 17 18 16 15 14 12 13 19 APRum_TUONO_MY05_01_UK book Page...

Page 11: ... panel 9 Fuel tank 10 Coolant expansion tank cap 11 Fuel tank filler cap 12 Air filter 13 Right rear view mirror 14 Front brake fluid tank 15 Right headlight 16 Right side fairings 17 Horn 18 Expansion tank 19 Rear brake fluid tank 20 Rear brake master cylinder 21 Rear brake control lever 22 Rider right footrest 22 2 3 1 21 10 11 9 12 13 4 5 6 7 8 20 19 18 16 17 15 14 APRum_TUONO_MY05_01_UK book P...

Page 12: ...g lock 3 Instruments and indicators 4 Front brake lever 5 Throttle grip 6 High beam flasher passing button 7 Dimmer switch 8 Turn indicator switch 9 Horn button 10 TRIP 1 TRIP 2 MODE switch 11 Engine kill switch 12 Starter button 12 11 6 8 10 7 1 4 5 2 3 9 APRum_TUONO_MY05_01_UK book Page 12 Monday September 26 2005 5 15 PM ...

Page 13: ...Multifunction digital display coolant temperature clock battery voltage lap timer engine oil pressure diagnostics 6 Blue high beam warning light 7 Amber low fuel warning light 8 Green turn indicator warning light 9 Red line light 1 2 3 4 5 6 7 8 9 INSTRUMENTS AND INDICATORS APRum_TUONO_MY05_01_UK book Page 13 Monday September 26 2005 5 15 PM ...

Page 14: ...is operated Side stand down light Turns on when the side stand is down Low fuel warning light It comes on when the quantity of fuel left in the tank is approx 4 5 1 b In this case top up as soon as possible see page 29 FUEL Neutral indicator warning light Comes on when the gear is in neutral Error warning light Comes on when the ignition switch is set to with the engine stopped as a lamp test If t...

Page 15: ...and check coolant level see page 37 COOLANT Contact an aprilia Authorised Dealer If the maximum allowed temperature is exceeded 115 C 239 F the engine may be seriously damaged Clock Displays time hour and minutes as preset see page 16 MULTIFUNCTION COMPUTER Battery voltage V BATT Displays the battery voltage in Volts see page 16 MULTIFUNCTION COMPUTER Lap timer Displays the different lap times as ...

Page 16: ...hows the Tuono 1000 logo The pointer of revolution counter 3 reaches the set gear shift value rpm and then goes back immediately to zero During the initial check up all instruments will briefly show the current values of the corresponding parameters When the key is on the following standard settings are displayed Clock or lap timer zone A Current speed zone B Odometer zone C Coolant temperature zo...

Page 17: ...et all data from selected TRIP meter Mode MODE configuration features the functions allowing the user to interact with the system Set selector 1 to MODE position to select MODE configuration While the vehicle at rest the following data are alternately displayed every time the SET button 2 is pressed CURRENT SPEED BATTERY VOLTAGE Press SET 2 button for several seconds to enter the configuration men...

Page 18: ...his mode allows you to set the clock In this function hours increase by one unit every time the SET button 2 is pressed when value is 12 it goes back to 1 if the SET button 2 is pressed again AM indication becomes PM or vice versa when time goes from 11 59 to 12 00 Press the SET button 2 for several seconds to store the value and go to minutes setting mode Minutes increase by one unit every time t...

Page 19: ...TTINGS menu When battery is connected for the first time the instrument panel sets to running in rpm value the next time battery is connected it sets to last set value RUNNING IN RPM 6000 MINIMUM RPM 5000 MAXIMUM RPM 12000 When the set threshold is exceeded the alarm light 4 on the instrument panel flashes until the value goes below the threshold BACK LIGHTING This function allows you to set backl...

Page 20: ...conds the operation is aborted When the second key is acknowledged the new code is requested with the message INSERT THE NEW CODE Once the operation is over the display goes back to DIAGNOSIS menu If you entered with the code this operation will not be allowed Once the operation is over the instrument panel goes back to SETTINGS menu C F This function allows you to select the unit of measurement f...

Page 21: ... time measurement is cancelled and a new one is started Press again the SET button 2 after 10 seconds have elapsed from timer start time measurement is stopped stored and a new one is started Stop the time measurement session by pressing the SET 2 push button for several seconds Acquisition ends as soon as 40 lap times are stored FULL is displayed Stop the vehicle see page 54 STOPPING and enter th...

Page 22: ... bottom D Alarms are divided in two groups depending on their priority High priority engine overtemperature engine oil pressure faults from E C U instrument panel faults Low priority turn indicators and control unit disconnect Should there be many alarms with same priority level the relevant icons are displayed alternatively High priority alarms do not allow you to display low priority ones If the...

Page 23: ...t CAUTION When the vehicle has come to a standstill and you have stopped the engine set the ignition switch to position 2 STARTER BUTTON When the starter button is pressed the starter motor will crank the engine For the starting procedure see page 48 STARTING CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR NOTE The electric components only operate when the ignition switch is in the position 3 Horn butt...

Page 24: ...d in case of peril and or emergency NOTE Release the button to turn off the high beam flasher 8 MULTIFUNCTION DISPLAY SET BUTTON NOTE To set functions see page 16 MULTIFUNCTION COMPUTER IGNITION SWITCH The ignition switch 1 is positioned on the upper plate of the steering column NOTE The key operates the ignition switch steering lock the fuel filler plug lock and the glove tool kit compartment cov...

Page 25: ...obiliser system is activated after the key is removed where immobiliser system is fitted Neither the engine nor the lights will operate It is possible to remove the key The immobiliser system is activated after the key is removed where immobiliser system is fitted The engine and the lights can be operated It is not possible to remove the key The steering is locked It is not possible to start the e...

Page 26: ...r seat seat cover 2 make sure that you have not left the key in the glove tool kit compartment To lock the passenger seat seat cover 2 u Slide the lower front lugs underneath the frame tube of the rear subframe u Position passenger seat seat cover and press down until the lock snaps shut WARNING Before riding make sure that the passenger seat seat cover 2 is properly locked WARNING Passenger seat ...

Page 27: ... double socket spanner 4 17 mm open end spanner 5 16 mm socket spanner for spark plug 6 double ended cross headed hexagon screwdriver 7 tool box 8 fuse puller 9 Maximum allowed weight 1 5 kg LUGGAGE FIXING POINTS The passenger seat can be used to carry small luggage which must be strapped down securely to the suitable fixing points 9 Maximum allowed weight 9 kg WARNING Carry small luggage only and...

Page 28: ...ning of the vehicle on the rear stand Rear support stand 2 see page 67 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND Engine oil and engine oil filter change Rear wheel disassembly Drive chain adjustment Removal of the lower fairing Front support stand 3 see page 68 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND Front wheel disassembly Click clamp 4 installation pliers see page 61 CLICK CLA...

Page 29: ... the fuel with the skin and the inhalation of vapours do not swallow fuel or pour it from a receptacle into another by means of a tube DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN Use only premium grade unleaded fuel with a minimum octane rating of 95 RON and 85 MON To refuel proceed as follows u Raise the flap 1 u Insert the key 2 into the tank plug lock 3 u Turn the key cloc...

Page 30: ...specially after maintenance or inspections Check that the brake lines are neither twisted nor worn out Prevent water or dust from accidentally getting into the circuit In case maintenance operations are to be performed on the hydraulic circuit it is advisable to use latex gloves If the brake fluid gets in contact with the skin or the eyes it can cause serious irritations WARNING Carefully wash the...

Page 31: ... fitted to the right side of the wheel The following information refers to a single braking system but is valid for both When the disc pads wear out the level of the fluid decreases to automatically compensate for their wear The front brake fluid reservoir is mounted near the front brake lever coupling The rear brake fluid reservoir is located under right side fairing remove the right side fairing...

Page 32: ...e level of the fluid decreases progressively to compensate for their wear u Check the brake pad wear see page 90 CHECKING THE BRAKE PADS FOR WEAR and the disc wear If the pads and or the disc do not need replacing provide for topping up TOPPING UP Carefully read page 30 BRAKE FLUID recommendations CAUTION The brake fluid may flow out of the tank Do not operate the front brake lever if the screws 1...

Page 33: ...o the fluid If you use a funnel or other similar items make sure that they are perfectly clean u Top up the reservoir 2 by adding brake fluid see page 114 LUBRICANT CHART until exceeding MIN level mark CAUTION While topping up never pour too much fluid Fill up to max level only with new brake pads If topped up to max level with worn pads brake fluid will spill out when you change the pads at a lat...

Page 34: ...ke fluid reservoir plug has been loosened or removed WARNING Avoid long exposure of brake fluid to air The brake fluid is hygroscopic and when in contact with the air it absorbs its humidity WARNING Leave the brake fluid tank open ONLY for the time necessary for topping up u Unscrew the screw 3 completely u Shift the complete reservoir 1 moderately outwards u Unscrew and remove the plug 2 CAUTION ...

Page 35: ...ed Dealer CAUTION Make sure the clutch hose is not twisted or worn Prevent water or dust from accidentally getting into the circuit In case maintenance operations are to be performed on the hydraulic circuit it is advisable to use latex gloves Clutch fluid is an irritant Avoid contact with eyes or skin In the event of accidental contact flush affected area thoroughly Obtain medical attention or if...

Page 36: ...thorised Dealer If the vehicle is used for racing have the clutch checked every 5000 km 3120 mi by an aprilia Authorised Dealer NOTE The engine is equipped with a hydraulically operated clutch aided by the patented PPC Pneumatic Power Clutch system which prevents rear wheel bouncing under braking CHECK u Place the vehicle in vertical position and keep handlebar in the direction of travel u Make su...

Page 37: ...el that is in between the marks MIN and MAX CAUTION Never exceed the MAX level Check the clutch for proper operation When the clutch lever has exceeding travel or if you notice a loss of efficiency contact an aprilia Authorised Dealer The clutch hydraulic circuit may need bleeding COOLANT CAUTION Do not ride when coolant is below the minimum level LOW NOTE You will need to remove the right side fa...

Page 38: ...eeze This mixture is ideal for most operating temperatures and ensures good protection against corrosion It is advisable to keep the same mixture also in the hot season since in this way losses due to evaporation are reduced and it is not necessary to top up very frequently The mineral salt deposits left in the radiator by evaporated water are thus reduced and the efficiency of the cooling system ...

Page 39: ...nt is toxic when ingested Contact with eyes or skin may cause irritation Do not use your fingers or any other object to check if there is enough coolant CAUTION Do not put additives or other substances into the fluid If you use a funnel or other similar items make sure that they are perfectly clean u Top up the expansion tank by adding coolant see page 114 LUBRICANT CHART until this almost reaches...

Page 40: ... the wear of the tyres since tyres in bad conditions can impair both the grip and the vehicle handling Some of the tyres approved for this vehicle are equipped with wear indicators There are several kinds of wear indicators For more information on how to check the tyres for wear contact your Dealer Visually inspect the tyres for wear and have them changed if worn Change the tyre when it is worn ou...

Page 41: ...ion should be required it is advisable to use latex gloves CAUTION If the light comes on during regular engine operation and on the same time even the symbol is on it means that the engine oil pressure in the circuit is low In this case check the engine oil level see page 62 CHECKING AND TOPPING UP ENGINE OIL LEVEL if the level is not correct stop the engine immediately and contact an aprilia Auth...

Page 42: ... is possible to adjust the brake control lever clearance u Slacken the lock nut 4 u Unscrew the master cylinder actuating rod 5 to ensure a minimum clearance of 0 5 1 mm between the rod and the piston CAUTION Make sure that the lever 6 has a certain amount of free play or the brake will remain applied leading to early wear of braking elements Lever 6 idle stroke 4 mm measured at the lever end u Lo...

Page 43: ...ners are warned that the law may prohibit the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use the use of the vehicle after such device or element of design has ...

Page 44: ...the left side and always with extended side stand CAUTION Do not apply the load of your weight or of the passenger s weight onto the side stand The stand has been designed to support the weight of the vehicle and a minimum load without the rider and the passenger The purpose of placing the vehicle on the side stand before mounting is to keep the vehicle from falling or overturning This does not me...

Page 45: ...traighten the vehicle into riding position while keeping it in balance NOTE The rider must not extract or attempt to extract the passenger footrest while seated astride the vehicle because this might compromise the stability and balance of the vehicle u Have the passenger extract the two passenger footrests u Instruct the passenger on how to safely get on the vehicle u Kick the side stand complete...

Page 46: ...it capable of detecting abnormal operation in real time and storing faults Each time the ignition key is set to the word SERVICE 1 appears on the right side of the multifunction display for approximately three seconds CAUTION If the wording SERVICE 1 is displayed during normal engine operation it means that the Engine Control Unit has detected a fault In many cases the engine keeps running with li...

Page 47: ... clutch must work without snatching and or slipping 35 36 Steering Make sure that the steering rotates smoothly without any clearance or looseness Side stand Make sure that it operates correctly Make sure that when the stand is let up or down there is no friction and that the spring tension brings it back to its normal position If necessary lubricate joints and articulations Make sure that the saf...

Page 48: ...e if you try to engage the gears the engine stops With the side stand up it is possible to start the engine either in neutral gear or with engaged gears and pulled in clutch lever u Get on the vehicle in riding position see page 44 INSTRUCTIONS FOR USE u Make sure that the stand is completely up u Make sure that the dimmer switch 1 is in position u Set the engine stop switch 2 to position u Turn t...

Page 49: ...start within fifteen seconds wait ten seconds before operating the starter button again u Press the starter button 10 do not open the throttle yet and release the button as soon as the engine starts CAUTION Avoid pressing the starter button 10 when the engine is running or the starter motor may damage If the engine oil pressure symbol is displayed it means that engine oil pressure in the circuit i...

Page 50: ...your hands on the grips and your feet on the footrests NEVER RIDE IN ANY POSITION OTHER THAN THOSE INDICATED WARNING If you ride with a passenger instruct him her so that he she does not create problems during manoeuvres Before leaving make sure that the stand is completely up To leave u Start the engine see page 48 STARTING u Adjust the inclination of the rear view mirrors correctly CAUTION With ...

Page 51: ...low rpm u Release the throttle grip 2 Pos A pull the clutch lever 3 and lift the gear shift lever 4 Release the clutch lever 3 and accelerate u Repeat the last two operations and shift up CAUTION If the engine oil pressure logo comes on during regular engine operation it means that engine oil pressure in the circuit is low In this case stop the engine immediately and contact an aprilia Authorised ...

Page 52: ...ICE is displayed on the right side during normal engine operation it means that the Engine Control Unit has detected a fault In many cases the engine keeps running with limited performance contact an aprilia Authorised Dealer immediately To avoid the overheating of the clutch keep the engine running with vehicle at rest engaged gears and pulled clutch lever for the shortest time possible WARNING A...

Page 53: ... grip and fall down WARNING Pay the utmost attention to any obstacle or variation of the ground Uneven road surfaces rails inspection covers painted signals construction site metal covers become slippery in rainy weather and must be negotiated carefully smoothly and keeping the vehicle upright Always signal your intention to change lanes or direction in good time using the direction indicators Avo...

Page 54: ...After running in of the regular service intervals chart see page 59 REGULAR SERVICE INTERVALS CHART in order to avoid hurting yourself or other people and or damaging the vehicle u Between the first 1000 625 mi and 1500 km 937 mi ride more briskly change speed and use the maximum acceleration only for a few seconds in order to ensure better coupling of the components never exceed 7500 rpm see tabl...

Page 55: ... excessive inclination of the vehicle may cause the fuel to flow out of the tank The fuel used for internal combustion engines is extremely inflammable and in particular conditions it can become explosive WARNING Do not apply the load of your weight or of the passenger s weight onto the side stand To park the vehicle u Choose a suitable parking area u Stop the vehicle see page 54 STOPPING u Set th...

Page 56: ... follows WARNING Make sure that the parking surface is free from obstacles firm and flat u Choose a suitable parking area see page 55 PARKING u Grasp the left grip 1 and place your right hand on the rear upper part of the vehicle 2 u Press the side stand with your right foot and extend it completely 3 u Incline the vehicle until the stand rests on the ground u Steer the handlebar completely leftwa...

Page 57: ... time the ignition key is removed from the switch Store the spare key in a safe place Immobiliser system keys cannot be duplicated If both keys are lost you will have to have a number of vehicle components replaced rather than just the key operated locks Embedded in the key grip is a transponder an electronic device that modulates the radiofrequency signal emitted by a special antenna built into t...

Page 58: ...case periodic maintenance operations assistance or technical advice are needed contact an aprilia Authorised Dealer who will ensure you prompt and accurate servicing Ask your aprilia Authorised Dealer to test the vehicle on the road after a repair or periodic maintenance operation In any case personally carry out the Preliminary checking operations after any maintenance operation see page 47 PRE R...

Page 59: ...t After running in 1000 km 625 mi Every 5000 km 3125 mi only for racing use Every 10000 km 6250 mi or 12 months Every 20000 km 12500 mi or 24 months Spark plug e c e Air filter e c e Engine oil filter e e e Engine oil filter on oil tank d d d Light operation direction c Light system c c Safety switches Clutch fluid c c c Brake fluid c c c Coolant c c c Engine oil e e e Tyres c c Tyre pressure f f ...

Page 60: ...0000 km 6250 mi c Transmission cables and controls c c c Rear suspension linkage bearings c Steering bearings and steering clearance c c c Wheel bearings c c Brake discs c c c General running of the vehicle c c c Adjusting the valve clearance f f Braking systems c c c Cooling system c c Clutch fluid every 12 months e every 24 months e Brake fluid Coolant Fork oil after the first 10000 km 6250 mi a...

Page 61: ...kage and protect the components positioned near the joint CLICK CLAMPS For the removal it is sufficient to use simple pliers while for the installation it is necessary to use a special tool see below Before removing a clamp prepare the material necessary for the correct reassembly NOTE Have the appropriate special tool at hand clamp installation pliers see page 28 SPECIAL TOOLS CAUTION Upon instal...

Page 62: ...at the engine oil pressure symbol A does not show on multifunction display see page 14 INSTRUMENTS AND INDICATORS TABLE NOTE To warm the engine and have the engine oil reach the operating temperature do not let the engine idle with the vehicle at rest According to the correct procedure it is advisable to carry out the check after a trip or after covering approximately 15 km 10 mi on a road outside...

Page 63: ...age 41 ENGINE OIL NOTE Halve maintenance intervals if you are riding in rainy or dusty conditions on rough road surfaces or when the vehicle is used in competitions Periodically check the engine oil level see page 62 CHECKING AND TOPPING UP ENGINE OIL LEVEL change the oil after the first 1000 km 625 mi and successively every 10000 km 6250 mi CAUTION If the vehicle is used for racing change engine ...

Page 64: ...OSE OF THE OIL IN THE ENVIRONMENT Dispose of engine oil stored in a sealed container through the nearest waste oil reclamation firm or through the supplier u Remove any metal debris collected by the drain plug 4 magnet u Screw and tighten the drain plug 4 Drain plug 4 tightening torque 12 Nm 1 2 kgm CHANGING THE ENGINE OIL FILTER NOTE Halve maintenance intervals if you are riding in rainy or dusty...

Page 65: ...screw clamp 10 or with other types of clamps u Release the click clamp 11 u Disconnect the hose 12 u Release and remove the engine oil filter 9 located on the reservoir and clean with an air line u Check the engine oil filter 9 seal fit and tighten the filter Engine oil filter 9 tightening torque 30 Nm 3 kgm u Connect the hose 12 and fit a new click clamp CAUTION Do not put additives or other subs...

Page 66: ...LLUTING PRODUCTS INTO THE ENVIRONMENT u Every 10000 km 6250 mi remove the plug 1 drain its contents into a container and deliver it to a waste collection centre REMOVAL u Lift the fuel tank see page 77 LIFTING THE FUEL TANK u Release and remove the seven screws 2 u Take off the air box cover 3 u Unscrew and remove the two screws 4 u Remove the air filter retaining bracket 5 u Extract the air filte...

Page 67: ...ge a damaged air filter u Clean the outer surface of the air filter 6 with a clean cloth REPLACEMENT CAUTION Never reuse a filter u Replace the air filter 6 with a new air filter of the same type FITTING THE PINS FOR THE REAR WHEEL STAND u Position the vehicle on the stand see page 56 PLACING THE VEHICLE ON THE STAND Fit the pin 7 into the suitable seat in the swinging arm Start the screw 8 into t...

Page 68: ...STAND u Position the vehicle on the appropriate rear support stand see page 67 FITTING THE PINS FOR THE REAR WHEEL STAND u Slide both lugs of the stand 12 into the holes 13 at the bottom ends of the front fork u Place one foot on the front end of the stand 14 u Push down on the stand 14 CAUTION Make sure that the vehicle is stable FRONT WHEEL CAUTION Removing and refitting the front wheel may prov...

Page 69: ...t it correctly on assembly NOTE To facilitate the extraction of the wheel shaft slightly raise the wheel u Push on the threaded end of the wheel shaft 7 carefully Tap with a plastic mallet if needed u Hold the front wheel and withdraw the wheel shaft 7 manually u Remove the wheel by withdrawing it from the front CAUTION The spacer 6 should still be sitting in the wheel housing if it slips off refi...

Page 70: ... Wheel shaft clamp screws tightening torque 22 Nm 2 2 kgm u Slacken the two wheel shaft pinch bolts 5 on the left side u Refit the front brake callipers see page 71 FRONT BRAKE CALLIPERS u With pulled front brake lever press the handlebar repeatedly thrusting the fork downwards In this way the fork legs will settle properly u Place the vehicle on the side stand see page 67 POSITIONING THE VEHICLE ...

Page 71: ...alliper screws 1 CAUTION Do not operate the front brake lever when the callipers are not in place or the pistons might fall out leading to brake fluid spillage In this case consult an aprilia Authorised Dealer who will carry out the proper maintenance operation Withdraw the brake calliper 2 from the disc leaving it attached to the hose 3 Remove the other brake calliper as follows u Repeat the oper...

Page 72: ...el you will need the rear wheel stand Make sure to have it ready at hand DISASSEMBLY u Position the vehicle on the appropriate rear support stand 1 see page 67 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND u Place a support 2 under the tyre to hold the wheel in place once released Wheel nut 3 tightening torque 120 Nm 12 kgm u Undo and remove the wheel hub nut 3 and collect the washer 4 NOTE To...

Page 73: ...will come off and the sprocket 9 might damage NOTE The removal of the final drive unit is not necessary if the wheel is in the normal running position vertical or in horizontal position with the rear sprocket facing upwards and in both cases secured against overturning NOTE Do not unscrew the five nuts 16 The whole final drive unit must be withdrawn from the flexible coupling holder u Place both h...

Page 74: ... wheel shaft 5 see page 114 LUBRICANT CHART Danger of injury Do not insert your fingers to align the holes u Move the wheel backwards until its central hole and the holes on the swinging arm are aligned u Rotate the carrier 12 complete with brake calliper 13 it will pivot around the locating pin 17 until matching the holes u Push the wheel shaft 5 fully home from the right side NOTE Make sure the ...

Page 75: ...t of the chain lower section midway between the sprockets Movement should be approximately 25 mm u Move the motorcycle forward in such a way as to check the vertical oscillation of the chain even in other positions the slack must be constant in all the wheel rotation phases CAUTION If in some positions the slack is higher than in others this means that there are crushed or seized links in this cas...

Page 76: ...d and made work again If this is not possible contact an aprilia Authorised Dealer who will provide for changing the chain CLEANING AND LUBRICATION CAUTION The drive chain links are fitted with O rings that retain the grease inside Carry out the adjustment lubrication cleaning and change of the chain with great care Never wash the chain with water jets steam jets high pressure water jets and highl...

Page 77: ...isk of fire Wait until the engine and the exhaust silencer have completely cooled down Fuel vapours are noxious for your health Before proceeding make sure that the room in which you are working is properly ventilated Do not inhale fuel vapours Do not smoke or use open flames DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT u Remove the rider seat see page 77 REMOVING THE RIDER SEAT u Remove the side pan...

Page 78: ... see page 56 PLACING THE VEHICLE ON THE STAND CAUTION Handle the plastic and painted components with care to avoid scraping or damaging them u Unscrew and remove the two retaining screws 1 and collect the washers u Remove the fairing 2 u Unscrew and remove the retaining pin 3 u Unscrew and remove the retaining screw 4 and collect the washer 1 2 1 4 3 APRum_TUONO_MY05_01_UK book Page 78 Monday Sept...

Page 79: ...e the hose 5 u Remove the fairing 6 u Release and remove the retaining screw 7 u Remove the fairing 8 u Unscrew and remove the two retaining screws 9 and collect the washers u Remove the fairing 10 5 6 8 7 9 10 APRum_TUONO_MY05_01_UK book Page 79 Monday September 26 2005 5 15 PM ...

Page 80: ...screw 11 and collect the washer u Unscrew and remove the left retaining screw 12 and collect the washer u Unscrew and remove the right retaining screw 13 and collect the washer u Remove the fairing 14 11 12 13 14 APRum_TUONO_MY05_01_UK book Page 80 Monday September 26 2005 5 15 PM ...

Page 81: ...ve the fairing 16 u Unscrew and remove the two retaining screws 17 and collect the washers u Unscrew and remove the retaining pin 18 u Remove the fairing 19 u Unscrew and remove the retaining screw 20 u Remove the fairing 21 16 15 15 17 18 19 17 21 20 APRum_TUONO_MY05_01_UK book Page 81 Monday September 26 2005 5 15 PM ...

Page 82: ...th care to avoid scraping or damaging them u Remove the side body panel 3 NOTE Make sure the rear fittings are positioned correctly on refitting Repeat these operations to remove the other side body panel NOTE The passenger seat lock or passenger seat cover will remain attached to the left side panel To separate them disconnect the Bowden cable from the lock on the inside of the side panel 2 1 3 A...

Page 83: ...hten the nuts to secure them firmly in place After refitting u Adjust the inclination of the rear view mirrors correctly REMOVING THE SIDE STAND Carefully read page 58 MAINTENANCE Removal of the side stand 1 is only recommended for vehicles used for racing the same applies to the following parts springs 2 bracket 3 stand switch 4 NOTE Removing the stand switch 4 interrupts the electric circuit To ...

Page 84: ...le of moving off with the stand down which may result in an accident leading to serious injury to the rider and other people and vehicle damage For the removal proceed as follows u Remove the left side fairing see page 82 REMOVING THE SIDE PANELS Do not pull on cables hoses connectors or on the wiring u Lift the tank see page 77 LIFTING THE FUEL TANK u Disconnect the electric connector 10 from the...

Page 85: ... correctly when you intend to use the vehicle on public roads u Refit the left side fairing see page 78 REMOVING THE SIDE FAIRINGS INSPECTING THE FRONT AND REAR SUSPENSIONS Carefully read page 58 MAINTENANCE NOTE Have the front fork oil changed by an aprilia Authorised Dealer for guaranteed accurate prompt service NOTE Halve maintenance intervals if the vehicle is used in rainy or dusty conditions...

Page 86: ...spension is managed by a hydraulic fork which is held to the steering tube by two yokes Each fork leg is fitted with suitable adjusters to modify suspension response An upper adjuster screw 1 controls rebound damping whereas a lower adjuster screw 2 controls compression damping A top mounted adjuster nut 3 controls spring preload SETTING THE FRONT FORK CAUTION Do not force the adjusters 1 2 beyond...

Page 87: ...public roads It is strictly prohibited to carry out adjustments for the use of the vehicle on racetracks and then ride it on roads or motorways clockwise anticlockwise Have this adjustment carried out exclusively by an aprilia Authorised Dealer For racing we recommend to fit the Öhlins multiadjustable front fork unit For the purchase contact an aprilia Authorised Dealer FRONT SUSPENSION Standard s...

Page 88: ...rebound a ring nut 2 for adjusting the spring preload and a locking ring nut 3 ADJUSTING THE REAR SHOCK ABSORBER NOTE Halve maintenance intervals if you are riding in rainy or dusty conditions on rough road surfaces or when the vehicle is used in competitions Check and if necessary adjust the rear shock absorber every 20000 km 12500 mi Factory setting is designed for racing However rear suspension...

Page 89: ... have to increase rebound damping accordingly to avoid unexpected jerking when riding If necessary contact your aprilia Authorised Dealer WARNING Racing settings may only be used during official competitions or sports events authorised by the competent authorities and taking place in closed circuits or anyway away from public roads It is strictly prohibited to carry out adjustments for the use of ...

Page 90: ...ollows u Position the vehicle on the stand see page 56 PLACING THE VEHICLE ON THE STAND NOTE The front right and left brake callipers are fitted with four brake pads each The rear brake calliper has two brake pads u Carry out a visual check between the disc and the pads proceeding front brake callipers 1 check the pads looking from above at the rear end from below at the rear to check the rear bra...

Page 91: ... 625 mi and successively every 10000 km 6250 mi The idle stroke of the throttle grip must be 2 3 mm measured on the edge of the grip itself If not proceed as follows u Position the vehicle on the stand see page 56 PLACING THE VEHICLE ON THE STAND u Take off the rubber gaiter 2 u Loosen the locknut 3 u Rotate the adjuster 4 until setting the specified free play u After adjusting tighten the locknut...

Page 92: ...cing In order to gain access to the spark plugs WARNING Before carrying out the following operations let the engine and the silencer cool down until they reach room temperature in order to avoid burns u Lift the fuel tank see page 77 LIFTING THE FUEL TANK NOTE The vehicle is equipped with one spark plug for each cylinder The procedures described below apply to both spark plugs For the removal proc...

Page 93: ...type of spark plugs only see page 110 TECHNICAL DATA in order not to compromise the life and performance of the engine Electrode gap should be checked using a wire gauge 7 to avoid damaging the platinum coating u Check electrode gap with a wire gauge 7 CAUTION Never attempt to adjust electrode gap Electrode gap should be 0 6 0 7 mm If not so change the spark plug u Make sure that the washer 8 is i...

Page 94: ...d to make sure the springs let it extend completely u Pull the stand midway up and let go to make sure the springs let it retract completely u The stand should turn smoothly smear the joint with grease if necessary see page 114 LUBRICANT CHART The side stand 1 is equipped with a safety switch 3 that inhibits ignition or stops the engine whenever a gear is engaged while the side stand 1 is down To ...

Page 95: ...Connect first the positive cable and then the negative cable Disconnect following the reverse order NOTE This vehicle is fitted with a maintenance free battery which seldom needs inspecting but may need charging from time to time CLEANING AND CHECKING BATTERY TERMINALS AND LEAD CONNECTIONS Carefully read page 95 BATTERY u Make sure that the ignition switch is in position u Remove the rider seat se...

Page 96: ...ider seat see page 77 REMOVING THE RIDER SEAT u Release and remove the negative terminal screw 1 u Slide the negative lead 2 aside u Lift the red protective cap 3 u Release and remove the positive terminal screw 4 u Move aside the positive cable 5 u Release and remove the two screws 6 u Remove the battery retaining bracket 7 u Grasp the battery 8 firmly and lift it out of its mount WARNING Once it...

Page 97: ...arger at hand u Set the battery charger to the desired charge rate see chart below u Connect the battery to the battery charger WARNING During the recharging or the use make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging u Switch on the battery charger WARNING Reassemble the battery only 5 10 minutes after disconnecting the recharge apparatus ...

Page 98: ...angle sensor on the battery bracket 2 u Fit and tighten the screws 3 WARNING Upon reassembly connect first the positive cable and then the negative cable u Connect the positive terminal by means of the screw 4 u Connect the negative terminal by means of the screw 5 u Coat the terminals of cables and battery with neutral grease or Vaseline u Refit the red protective cap 6 u Refit the rider seat see...

Page 99: ...ut once a month during the winter or when the vehicle remains unused in order to prevent the deterioration of the battery u Recharge it completely using a standard charge see page 97 CHARGING THE BATTERY If the battery remains on the vehicle disconnect the cables from the terminals CHECKING THE SWITCHES Carefully read page 58 MAINTENANCE The vehicle is provided with four switches 1 Stoplight switc...

Page 100: ...t and then the 30 A main fuses Check as follows u Set the ignition switch to position to avoid any accidental short circuit u Remove the rider seat see page 77 REMOVING THE RIDER SEAT u Open the cover of the auxiliary fuse box 1 u Extract and check the fuses one by one a divided link bar 2 means that the fuse is blown u Before replacing a fuse try to find out the cause of the trouble if possible u...

Page 101: ...ps camshaft position sensor ARRANGEMENT OF 20 A AUXILIARY FUSES F From ignition switch to high beam lights low beam lights NOTE There are three spare fuses G ARRANGEMENT OF 30 A MAIN FUSES H Battery charging and vehicle loads red and red white wires I Injection loads red and red white wires NOTE There is one spare fuse L VERTICAL ADJUSTMENT OF THE HEADLIGHT BEAM NOTE To check the direction of the ...

Page 102: ... headlights are also fitted with adjuster screws 2 for horizontal beam adjustment we advise against disturbing standard setting unless such adjustment is mandatory in your country Correct beam horizontal adjustment is performed at the factory TAPING OF THE HEADLIGHT If front lights are shielded with tape for track use it is recommended to disconnect the front light bulb connectors or the reflector...

Page 103: ...use its overheating and consequent breakage If you touch the bulb with bare hands remove any fingerprint with alcohol in order to avoid any damage DO NOT FORCE THE ELECTRIC CABLES NOTE Before changing a bulb check the fuses see page 100 REPLACING THE FUSES REPLACING THE INSTRUMENT PANEL LED If you need assistance or technical advice contact an aprilia Authorised Dealer who can ensure you prompt an...

Page 104: ... change the bulbs u Position the vehicle on the stand see page 56 PLACING THE VEHICLE ON THE STAND HIGH AND LOW BEAM BULBS NOTE Disconnect one connector at a time to avoid confusing the various connectors when refitting When high and low beam bulb connectors must be removed at the same time mark them with their positions and make sure to refit them in the correct positions on assembly u Remove the...

Page 105: ...fit a new bulb of equal rating NOTE Make sure the bulb is correctly located in the bulb holder CHANGING THE FRONT AND REAR TURN INDICATOR BULBS Carefully read page 103 BULBS u Position the vehicle on the stand see page 56 PLACING THE VEHICLE ON THE STAND u Unscrew and remove the screw 1 CAUTION While removing the lens proceed carefully in order not to break the locating peg u Remove the lens 2 6 2...

Page 106: ...g CAUTION If the reflector 4 comes off its seat refit it correctly REPLACING THE NUMBER PLATE LIGHT BULB Carefully read page 103 BULBS u Position the vehicle on the stand see page 56 PLACING THE VEHICLE ON THE STAND u Remove passenger seat seat cover see page 26 UNLOCKING LOCKING THE PASSENGER SET SEAT COVER CAUTION To extract the bulb holder do not pull the electric wires u Extract the number pla...

Page 107: ...ticular conditions use of salt and anti ice chemical products on the roads during the winter Avoid leaving deposits of industrial and polluting powders tar spots dead insects bird droppings etc on the body Avoid parking the vehicle under trees since in some seasons residues resins fruits or leaves fall down which contain substances that may damage the paint WARNING After the vehicle has been washe...

Page 108: ...cately and rinsing frequently with plenty of water Polish with silicone wax only after having carefully washed the vehicle Do not use polishing paste on matt paints Do not wash the vehicle under the sun especially during the summer when the body is still warm since if the shampoo dries before being rinsed away it can damage the paint Do not use fluids at a temperature exceeding 40 C to clean the p...

Page 109: ... 40 TYRES u Place the vehicle in an unheated not humid room away from sunlight with minimum temperature variations u Wrap and tie a plastic bag around the exhaust pipe opening to keep moisture out NOTE Place the vehicle on the front and rear wheel stands so that both wheels are off the ground u Position the vehicle on the appropriate front support stand see page 68 POSITIONING THE VEHICLE ON THE F...

Page 110: ...m 1250 100 rpm Clutch multiplate wet clutch hydraulically operated control on left side of handlebar and PPC device Lubrication system dry sump with separate oil reservoir and oil cooler Air filter with dry filter cartridge Cooling liquid cooled TRANSMISSION Type mechanical 6 gears with foot control on the left side of the engine CAPACITY Fuel reserve included 18 b Fuel reserve 4 1 b Engine oil oi...

Page 111: ...l minimum octane rating 95 ROM and 85 MON FRAME Type double beam inclined in aluminium alloy box type Steering head angle 25 Trail 101 7 mm with tyre 120 70 SUSPENSIONS Front adjustable hydraulic upside down fork Ø 43 mm Stroke 120 mm Rear aluminium alloy double sided swinging arm with progressive linkage and APS system Adjustable hydraulic shock absorber in rebound and compression damping Wheel t...

Page 112: ...0 ZR 17 Rear 180 55 ZR 17 190 55 ZR17 SPARK PLUGS Standard NGK R DCPR9E Spark plug gap 0 6 0 7 mm Resistance 5 kΩ ELECTRIC SYSTEM Battery 12 V 10 Ah Main fuses 30 A Auxiliary fuses 5 A 15 A 20 A Generator with permanent magnet 12 V 500 W BULBS Halogen low beam 12 V 55 W H11 x 2 Halogen high beam 12 V 55 W H11 x 2 Front parking light 12 V 5 W x 2 Direction indicators 12 V 10 W AMBER USA version 12 ...

Page 113: ...ONO R 113 WARNING LIGHTS Neutral LED Direction indicators LED Fuel reserve LED High beam LED Stand down LED Warning light LED Red line setting LED Immobiliser LED APRum_TUONO_MY05_01_UK book Page 113 Monday September 26 2005 5 15 PM ...

Page 114: ...ASE 30 As an alternative to recommended grease use top brand rolling bearing grease that will resist a temperature range of 30 C 140 C with drip ping point 150 C 230 C high corrosion protection good resistance to water and oxidisation Battery lead protection Neutral grease or Vaseline Spray grease for chains recommended CHAIN SPRAY or CHAIN LUBE WARNING Use new brake fluid only Do not mix differen...

Page 115: ...use and maintenance RSV 1000 TUONO R 115 NOTE ASK FOR GENUINE SPARE PARTS ONLY APRum_TUONO_MY05_01_UK book Page 115 Monday September 26 2005 5 15 PM ...

Page 116: ... R M V R N Gr Bi Bi M V B V B V B V M V R Gr Bi Ro Bi V Bi Az Gr B V M N G R B Ar M V Bi B M Vi Ro M Bi N Ar Gr B G V B V Bi G Gr Gr N B V Az Ar V Bi X1 R N N Ro N B Ar Bi X2 R Gr V G N Vi N M Bi M G Gr R G B Ro Az G Gr Vi Bi Vi G B R Bi R Az V B Ar Gr Bi V B Ar Gr Bi R M COILS FAN RELAY INTAKE FLAP PURGE VALVE CAMS INJECTORS E 15A HIGH LOW BEAM LIGHTS F 8 N G N Az Bi V N R B Ro N V Gr B G 62 B G ...

Page 117: ... Right dimmer switch 35 Rear stoplight switch 36 Rear right turn indicator 37 Tail light LED 38 39 Speed sensor 40 Voltage regulator 41 Warning horn 42 Clutch switch 43 Front stoplight switch 44 Rear left turn indicator 45 Auxiliary fuses 46 Flywheel 47 Multiple connectors 48 Bank angle sensor 49 Lambda sensor 50 ECU diagnostics 51 Front right turn indicator 52 Right beam parking light 53 Left hig...

Page 118: ...118 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance RSV 1000 TUONO R APRum_TUONO_MY05_01_UK book Page 118 Monday September 26 2005 5 15 PM ...

Page 119: ...use and maintenance RSV 1000 TUONO R 119 NOTE ASK FOR GENUINE SPARE PARTS ONLY APRum_TUONO_MY05_01_UK book Page 119 Monday September 26 2005 5 15 PM ...

Page 120: ...ion of the Authorised Dealer and or Service Centre nearest you please consult the Yellow Pages or the map provided at our web site www aprilia com When you demand aprilia Original Parts you are purchasing products that have been developed and tested as early as the vehicle design stage aprilia Genuine Parts systematically undergo strict quality control procedures to ensure total reliability and lo...

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