APRILIA TUONO 1000 R Workshop Manual Download

Page: 259 / 279

CYCLE PARTS

7 - 4

TUONO 1000

Key:

1. RPM

sensor

2. Lambda

sensor

3. Camshaft

sensor

Coolant temperature sensor

Intake air temperature sensor

Bank angle sensor

7. Vehicle

speed

sensor

8. Injector
9. Ignition

coils

10. Throttle position sensor (TPS)
11. Immobilizer

antenna

12. Starter

motor

13. Stepper

motor

14. Generator
15. Recharge

voltage

16. Fuel

pump

17. Fuel reserve sensor
18. Control

unit

19. Headlight
20. Tail

light

21. Auxiliary

fuses

22. Main

fuses

23. Intake pressure sensor

Summary of Contents for TUONO 1000 R

Page 1: ...www serviceaprilia com workshopmanual TUONO 1000 1306 5 12 2005 00 8104982 UK ...

Page 2: ...INTRODUCTION 0 1 TUONO 1000 INTRODUCTION 0 ...

Page 3: ...INTRODUCTION 0 2 TUONO 1000 SUMMARY 0 1 FOREWORD 3 0 1 1 FOREWORD 3 0 1 2 REFERENCE MANUALS 4 0 1 3 ABBREVIATIONS SYMBOLS 5 ...

Page 4: ...s in repair procedures are communicated to all aprilia dealers and agencies world wide Such modifications will be included in subsequent editions of the manual Should you require assistance or clarifications regarding inspection and repair procedures please contact the aprilia SERVICE DEPT which will be pleased to help as well as providing you with updates and technical modifications regarding the...

Page 5: ...OLS MANUALS aprilia part description 001A00 OWNER S MANUALS aprilia part description 8104927 8104928 8104929 8104930 CHASSIS WORKSHOP MANUAL aprilia part description 8104978 8104981 8104979 8104980 8104982 8104983 ENGINE TECHNICAL MANUAL aprilia part description 8140743 8140744 8140745 8140746 8140747 8140748 ...

Page 6: ...mshaft ECU Electronic Control Unit rpm revolutions per minute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardisation Organisation kg kilograms kgm kilograms per metre 1 kgm 10 Nm km kilometres km h kilometres per hour kΩ kilo Ohm kPa kiloPascal 1 kPa 0 01 bar KS clutch side from the German Kupplungsseite kW kilowatt ℓ litres LAP racetrack lap LED Light Emitting Diode LEFT...

Page 7: ...ght side SAE Society of Automotive Engineers TEST diagnostic check T B E I crown head Allen screw T C E I cheese head Allen screw T E hexagonal head T P flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V volt W watt Ø diameter ...

Page 8: ...GENERAL INFORMATION 1 1 TUONO 1000 GENERAL INFORMATION 1 ...

Page 9: ...ANUAL 3 1 1 1 CONVENTIONS USED IN THE MANUAL 3 1 1 2 SAFETY WARNINGS 4 1 2 GENERAL RULES 5 1 2 1 BASIC SAFETY RULES 5 1 3 DANGEROUS ELEMENTS 8 1 3 1 WARNINGS 8 1 4 RUNNING IN 11 1 4 1 RUNNING IN 11 1 5 VEHICLE IDENTIFICATION 12 1 5 1 POSITION OF THE SERIAL NUMBERS 12 ...

Page 10: ...are referred to the rider seated on the vehicle in the normal riding position Motorcycle operation and basic maintenance are covered in the OWNER S MANUAL In this manual any variants are identified with these symbols optional catalytic version all versions MP national certification SF European certification EURO 1 limits VERSION Italy Greece Malaysia United Kingdom Holland Chile Austria Switzerlan...

Page 11: ...potential risk of personal injury Disregarding the instructions identified by this symbol may compromise the safety of the user the motorcycle and third parties DANGER Indicates a potential hazard which may result in serious injury or even death WARNING Indicates a potential hazard which may result in minor personal injury or damage to the vehicle NOTE The word NOTE in this manual precedes importa...

Page 12: ... components of the exhaust system become very hot and remain hot for some time after the engine has been stopped Wear insulating gloves before handling these components or allow for the engine and the exhaust system to cool down before proceeding USED GEARBOX AND FORK FLUIDS DANGER Wear latex gloves when servicing Prolonged or repeated contact with gear fluid may cause severe skin damage Wash your...

Page 13: ...e sure that the electrolyte acid is suitable for the type of battery used GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing disassembling or reassembling the motorcycle or its components DANGER Using bare flames is strictly forbidden when working on the motorcycle Before servicing or inspecting the motorcycle stop the engine and remove the key from the ignition s...

Page 14: ...ave a damaged thread Lubricate the bearings abundantly before assembly Make it a rule to check that all components you have fitted are correctly in place After repairing the motorcycle and after each service inspection perform the preliminary checks and then test ride the motorcycle in a private estate area or in a safe area away from traffic Clean all mating surfaces oil seal edges and gaskets be...

Page 15: ...ycle Failure to maintain the lubricant level or the use of incorrect old or dirty lubricant can cause the engine or transmission to seize resulting in accident serious injury or death Prolonged or repeated contact with gear fluid may cause severe skin damage Wash your hands thoroughly after use Do not dispose of oil in the environment For disposal contact the nearest waste oil reclamation firm or ...

Page 16: ... open or in storage for long periods of time Any sudden changes in slack or hardness in the brake levers are warning signs of problems with the hydraulic circuits Ensure that the brake discs and brake linings have not come in contact with oil or grease This is particularly important after servicing or inspections Ensure that the brake lines are not twisted or worn Avoid accidental entry of water o...

Page 17: ...ocket DANGER Improper maintenance can cause premature wear of the chain and result in damage to both the front and rear sprocket Perform chain maintenance operations more frequently if the vehicle is used on dusty roads or in muddy areas TYRES WARNING An over inflated tyre results in a hard uncomfortable and less secure ride Over inflation also affects grip especially on curves and wet surfaces An...

Page 18: ... engine is running at low speed both during and after the running in period Until you have covered the first 100 km 62 mi use the brakes gently and avoid harsh prolonged braking This will help the brake pads bed in properly against the brake disc During the first 1000 km 621 mi never exceed 6000 rpm see table WARNING After covering the first 1000 km 621 mi perform the checks listed in the After ru...

Page 19: ...for vehicle registration NOTE Altering the vehicle s identification numbers is punishable by law with heavy fines and penalties Altering the frame number voids the warranty FRAME NUMBER The frame number 1 is stamped on the right hand side of the headstock ENGINE NUMBER The engine number 2 is stamped on the rear near the sprocket ...

Page 20: ...PERIODIC MAINTENANCE 2 1 TUONO 1000 PERIODIC MAINTENANCE 2 ...

Page 21: ...ON 3 2 1 1 TECHNICAL DATA 3 2 1 2 SCHEDULED MAINTENANCE CHART 6 2 1 3 LUBRICANT TABLE 8 2 1 4 TIGHTENING TORQUES 9 2 1 5 SPECIAL TOOLS 14 2 1 6 LOCATION OF KEY COMPONENTS 21 2 1 7 LOCATION OF INSTRUMENTS CONTROLS 23 2 1 8 INSTRUMENT PANEL OPERATION 25 2 1 9 SYSTEMS DIAGRAM 30 ...

Page 22: ...cooler Air filter Dry cartridge filter Cooling Liquid cooling GEARBOX Type mechanical 6 speed with control pedal on left side of engine CAPACITIES Fuel including reserve 18 l 4 76 gal Fuel reserve 4 1 l 1 06 0 26 l Engine oil gearbox 3700 cu cm 225 8 cu in gearbox and oil filter 3900 cu cm 238 9 cu in Fork fluid 505 2 5 cu cm 30 81 0 15 cu in each leg Coolant 2 2 l 0 58 gal 50 water 50 ethylene gl...

Page 23: ...0 ZR 17 250 2 5 36 25 PSI Rear PIRELLI DIABLO CORSA 190 50 ZR 17 280 2 8 40 61 PSI Front METZELER SPORTTEC M1 120 70 ZR 17 250 2 5 36 25 PSI Rear METZELER SPORTTEC M1 190 50 ZR 17 280 2 8 40 61 PSI Front MICHELIN PILOT SPORT E 120 70 ZR 17 TL 250 2 5 36 25 PSI Rear MICHELIN PILOT SPORT E 190 50 ZR 17 TL 280 2 8 40 61 PSI Front DUNLOP SPORTMA X D 208 RR 120 70 ZR 17 250 2 5 36 25 PSI Rear DUNLOP SP...

Page 24: ...V 500 W BULBS Low beam halogen 12 V 55 W H11 x 2 High beam halogen 12 V 55 W H11 x 2 Front parking light 12 V 5 W x 2 Turn indicators 12 V 10 W USA version 12V 10W Number plate light 12 V 5 W Rear parking stop lights LED Rev counter light LED Left multi function display light LED WARNING LIGHTS Gearbox in neutral LED Turn indicators LED Fuel reserve LED High beam light LED Stand light LED WARNING ...

Page 25: ... on uneven ground or for racing Components End of running in period 1000 Km 625 mi Every 5000 Km 3125 mi only for intensive racetrack use Every 10000 Km 6250 mi or 12 months Every 20000 Km 12500 mi or 24 months Spark plug 3 1 3 Air filter 3 1 3 Engine oil filter 3 3 3 Engine oil filter on oil tank 2 2 2 Operating setting of lights 1 Light system 1 1 Safety switches 1 1 Clutch fluid 1 1 1 Brake flu...

Page 26: ...0 mi or 24 months Rear shock absorber 1 1 Gearbox Every 10000 Km 6250 mi 1 Bowden cables and controls 1 1 1 Rear suspension connecting rod bearings 1 Steering bearings and steering play 1 1 1 Wheel bearings 1 1 Brake discs 1 1 1 Overall operation of vehicle 1 1 1 Valve clearance adjustment 4 4 Braking systems 1 1 1 Cooling system 1 1 Clutch fluid every 12 months 3 every 24 months 3 Brake fluid eve...

Page 27: ...EASE MP or Grease 30 As an alternative to recommended grease use top brand rolling bearing grease that will resist a temperature range of 30 C 140 C 22 F 284 F with dropping point 150 C 230 C 302 F 446 F high corrosion protection good resistance to water and oxidisation Battery terminals Neutral grease or Vaseline Chains RECOMMENDED aerosol chain lubricant CHAIN SPRAY or CHAIN LUBE Brake fluid REC...

Page 28: ... delivery line to throttle body 1 M12x1 5 22 72 78Kw reduction bushing 1 M5 3 shear bolt Loctite 243 SWINGARM Swingarm pivot ring nut 1 M30x1 5 60 Swingarm pivot adjustment bushing 1 M30x1 5 12 Swingarm pivot nut 1 M20x1 5 90 Calliper carrier retaining pin 1 M12 50 Loctite 243 Chain tightener screw and nut 1 1 M8 Man Rear brake line guide 3 M5 4 Chain guard upper fixing screw 1 M5 4 Chain guard an...

Page 29: ...M6 12 Voltage regulator mount 2 M6 10 Voltage regulator to mount 2 M6 10 Coil mount to frame 2 M6 10 Coil to coil mount 1 M6 10 ECU 3 M6 10 Starter relay mount to seat frame 1 M6 10 Relay carrier bracket to seat frame 2 M6 3 Atmospheric pressure sensor to seat frame cover 1 M5 1 Wire to starter motor 1 M6 5 Wires to starter relay 2 M6 4 Engine ground wire 2 M6 5 Main wiring harness plate to air in...

Page 30: ...rame 2 M6 10 Expansion tank cap 1 M28x3 6 Tube clamps no 8104097 4 FRONT BRAKING SYSTEM RH and LH front brake callipers 2 2 M10x1 25 50 Front brake fluid reservoir to bracket 1 M6 7 Front brake and clutch fluid reservoir bracket 1 M6 10 Clutch fluid reservoir to bracket 1 M5 3 Front brake line guide to bottom fork yoke 1 M5 4 Brake disc 6 6 M8 30 Loctite 243 REAR BRAKING SYSTEM Rear brake calliper...

Page 31: ...1 M20x1 5 30 Oil drain cap 1 M8 15 Oil sight glass 2 M10x1 20 SEAT FRAME LOWER COVER Lower cover to seat frame 3 M6 5 20 Seat frame lower cover to frame 2 M5 4 20 Rear stand bushing securing lower cover to seat frame 2 M6 12 20 NUMBER PLATE HOLDER Number plate holder to seat frame lower cover 4 M6 3 20 Cat s eye to number plate holder 2 M4 1 20 MUDGUARDS Front mudguard 4 M5 5 Rear mudguard 4 M5 5 ...

Page 32: ...NT FORK LOWER COVER Cover to bottom fork yoke 2 M6 3 Cover to bottom fork yoke with steering damper 1 M6 10 SEAT COVER Cover to cover base 7 SWP 3 9 1 HANDLEBAR AND CONTROLS Upper U bolt to handlebar mounts 4 M8 25 Handlebar mounts to fork top yoke for workshop manual only 2 M10 30 Loctite 243 Anti vibration weights 2 M6 10 Anti vibration weight end caps 2 M18x1 35 LH dimmer switch 1 M5x1 1 5 RH d...

Page 33: ...s Following is a list of special tools designed specifically for this vehicle If necessary request generic special tools WARNING Before using the special tools consult the provided documentation SUPPORT STANDS Pos aprilia part tool name and purpose A 8140176 complete support stands kit 1 8146486 front support stand 2 xxxxxxx N A central support stand 3 8705021 rear support stand xxxxxxx N A suppli...

Page 34: ... bracket FORK TOOLS Pos aprilia part tool name and purpose A 8140151 complete fork tool kit 1 8140145 tool for fitting Ø 41 mm seal 2 8140146 Weight to apply to tool aprilia part 8140145 tool for fitting Ø 41 mm Ø 1 61 in seal and aprilia part 8140189 tool for fitting oil seal for Ø 43 mm Ø 1 70 in hole Completes kit aprilia part 8140151 complete fork tool kit 3 8140147 tool for holding spacer 4 8...

Page 35: ...PERIODIC MAINTENANCE 2 16 TUONO 1000 ENGINE TOOLS ...

Page 36: ...ngs 13 0277729 drift for inserting lower counter shaft clutch cover brass bushings 14 8140177 spark plug spanner 15 0277252 tool for removing ignition cover 16 0277730 hexagonal bolt for extracting flywheel 17 0240880 threaded bolt for locking crankshaft at TDC 18 0277308 guide bushing for gearbox secondary shaft 19 8140178 drift for fitting and removing gudgeon pin 20 8140181 fuel oil compression...

Page 37: ...PERIODIC MAINTENANCE 2 18 TUONO 1000 MISCELLANEOUS TOOLS ...

Page 38: ... 10 8140432 impact puller 11 8140187 engine stand 12 8124838 M F battery charger 13 0897651 LOCTITE 243 blue 10 cu cm 0 61 cu in 14 0899788 LOCTITE 648 green 5 g 0 011 lb 15 0899784 LOCTITE 574 orange 16 0297434 LOCTITE 767 Anti Seize 15378 17 0297433 MOLYKOTE G N 50 g 0 11 lb 18 0897330 bp lz multipurpose grease 19 0297386 SILASTIC 732 RTV 100 g 0 22 lb 20 8116067 LOCTITE 8150 21 8202222 generic ...

Page 39: ...ne oil 8116053 Bimol Grease 481 grease 8116038 LUBERING ST grease xxxxxxx N A AP LUBE temporary lubricant xxxxxxx N A DID CHAIN LUBE grease 8116031 double solvent frame washing liquid 8116945 ACRILICON 28 cyanoacrylic glue xxxxxxx N A MOTUL MOTOWASH degreaser 8116043 ANTI SEIZE MOTAGEPASTE AS 1800 anti seize paste xxxxxxx N A alcohol 0898011 LOCTITE 275 fluorescent green xxxxxxx N A LOCTITE 572 xx...

Page 40: ...servoir 6 Left rear view mirror 7 Engine oil tank cap 8 Left side panel 9 Rider seat 10 Battery 11 Main fuse carrier 30A 12 Passenger seat lock glove tool kit compartment 13 Passenger left footrest Snaps closed open 14 Drive chain 15 Rear swingarm 16 Rider left footrest 17 Side stand 18 Gear change lever 19 Engine oil filter 20 Engine oil tank 21 Engine oil level ...

Page 41: ...ver 6 Control unit 7 Auxiliary fuse carrier 15A 8 Right side 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 reservoir 15 Right headlight 16 Right side fairings 17 Horn 18 Expansion tank 19 Rear brake fluid reservoir 20 Rear brake master cylinder 21 Rear brake lever 22 Rider right footrest ...

Page 42: ... Key 1 Clutch lever 2 Ignition steering lock switch 3 Instruments and indicators 4 Front brake lever 5 Throttle twistgrip 6 High beam flasher button 7 Light dimmer switch 8 Turn indicator switches 9 Horn button 10 TRIP1 TRIP2 MODE switch 11 Engine kill switch 12 Starter button ...

Page 43: ... light N 3 Amber stand down light 4 Red general warning light 5 Multifunction digital display coolant temperature clock battery voltage lap time engine oil pressure diagnostics 6 Blue high beam light 7 Amber low fuel light 8 Green turn indicator light 9 Red line light red ...

Page 44: ...ts will briefly show the current values of the corresponding parameters With the ignition key in position standard display readouts are as follows A CLOCK B CURRENT SPEED C ODOMETER D ENGINE TEMPERATURE TRIP 1 AND 2 TRIP 1 and 2 modes display trip meter readouts 1 and 2 Trip meter reading is displayed at the side of the measurement unit indication To select TRIP 1 or TRIP 2 mode set selector 1 to ...

Page 45: ...SETTINGS LAP TIMER DIAGNOSIS LANGUAGE SETTINGS When you select SETTINGS and hold down the SET button 2 to confirm a screen with the following options will appear EXIT TIME SETTINGS GEAR SHIFT INDICATOR BACKLIGHTING CHANGE THE CODE CODE RECOVERY C F TIME SETTINGS This option is used to set clock time At each press of the SET button 2 hour setting will increase by one unit from 1 to 12 and then will...

Page 46: ...ld down the SET button 2 and the instrument panel returns to the SETTINGS menu CHANGE THE CODE AND CODE RECOVERY This function can be used to change code provided that the old code is known Upon accessing this function the following message is displayed INSERT THE OLD CODE After the old code has been recognised a new code can be entered when the following prompt is displayed INSERT THE NEW CODE Wh...

Page 47: ...hold down the button to return to the LAP TIMER menu Recorded lap times will be lost if the battery is disconnected DELETE TIMES This function is used to delete recorded lap times You will be asked to confirm whether you intend to proceed before data is deleted When finished the display returns to the LAP TIMER menu Lap timer operation To use the lap timer select LAP TIME ON and hold down the SET ...

Page 48: ...r 1 000 Km 621 4 mi Afterwards every 10 000 Km 6213 7 mi ALARM DISPLAY If a severe failure such to lead to serious damage or affect safety is detected a symbol signifying its cause is shown in the lower portion of the display D Alarms are grouped into two priority classes High priority Engine overtemperature Engine oil pressure ECU errors Instrument panel errors Low priority Turn indicators and EC...

Page 49: ...PERIODIC MAINTENANCE 2 30 TUONO 1000 2 1 9 SYSTEMS DIAGRAM BRAKES ...

Page 50: ...PERIODIC MAINTENANCE 2 31 TUONO 1000 EXHAUST GAS RECOVERY ...

Page 51: ...FUEL SYSTEM 3 1 TUONO 1000 FUEL SYSTEM 3 ...

Page 52: ...T 16 3 2 2 REMOVING THE FUEL LEVEL SENSOR 17 3 2 3 REMOVING THE DELIVERY FUEL FILTER 18 3 2 4 REMOVING THE FUEL PUMP 19 3 3 THROTTLE BODY UNIT 21 3 3 1 REMOVING THE THROTTLE BODY UNIT 21 3 3 2 DISASSEMBLING THE THROTTLE UNIT 24 3 3 3 INSPECTING THE THROTTLE UNIT 27 3 3 4 REFITTING THE THROTTLE UNIT 28 3 3 5 REPLACING THE THROTTLE VALVE CONTROL LEVER 30 3 3 6 CHECKING AXIAL PLAY ON THE THROTTLE VAL...

Page 53: ...3 1 1 DIAGRAM Key 1 Fuel tank 2 Filler cap 3 Fuel pump unit 4 Breather tube for fuel vapours caused by tank overpressure 5 Excess fuel draining tube 6 Fuel level sensor 7 Delivered fuel filter 8 Fuel pump 9 Fuel delivery line 10 Fuel return line ...

Page 54: ...FUEL SYSTEM 3 4 TUONO 1000 3 1 2 INJECTION SYSTEM DIAGRAM ...

Page 55: ... Air temperature sensor 8 Throttle position sensor 9 Intake pressure sensor 10 Safety system side stand neutral sensor 11 Test switch 12 Bank angle sensor 13 Atmospheric pressure sensor 14 Oil pressure sensor 15 Electric fan 16 Automatic choke 17 Intake flap 18 Lambda sensor 19 Diagnosis connector 20 Starter relay 21 Fuel pump 22 Injector 1 23 Injector 2 24 Coil ...

Page 56: ... value be incorrect turn the FRONT CYLINDER bypass screw Read the residual CO value while alternatively opening the analyser valves Turn the bypass screws if the value does not stay between 0 7 and 1 2 and if the difference between the two readings is greater than 0 5 Once the CO test is completed ensure that the FRONT CYLINDER PRESSURE and REAR CYLINDER PRESSURE parameter values are approximately...

Page 57: ...etween 2 and 4 and if the difference between the two readings is greater than 0 5 Once the CO test is completed ensure that the FRONT CYLINDER PRESSURE and REAR CYLINDER PRESSURE parameter values are approximately within the specified range WARNING Should the bike be fitted with an Akrapovic complete exhaust system please note that the CO reading obtained with the approved exhaust system is lower ...

Page 58: ...y not mapped it is necessary to upload the suitable mapping see note concerning mapping parameter Aprilia software Meaningless field Revision number 47 Engine V2 60 990 Twin cylinder engine 60 V 990 cc Manufactured on dd mm yy ECU date of manufacture Mapping 664584 Mapping code stored in ECU Programming date dd mm yy Date last mapping was loaded day month year Last programmer 85456 ID code for the...

Page 59: ...re values Throttle offset V After the Initialisation or Throttle Pos Self Learn parameter is activated this value closed throttle position is stored in the ECU based on this reference value the control unit will know the position of the throttle at that moment Stepper motor Stepper idle motor steps if the signal is missing the ECU sets value 21 Battery voltage V Vehicle speed km h Front cylinder p...

Page 60: ... running Engine stop push button on off Engine kill push button status and immobilizer enable if OFF one or both devices are faulty Ignition request on off Correct operation can be tested with the gear engaged and by pressing the starter button under these conditions the ECU detects the start enable the Axone display will read on but will not start the engine as a safety precaution The Axone teste...

Page 61: ...vailable Water injection No ECU status that cannot be changed should read no Idling mot fitted Yes ECU status that can be changed with password authority only should usually read YES i e stepper motor available Purge valve yes no Parameter not active mechanical purge valve Electronic reverse No ECU status that cannot be changed should read no Electric starting Yes ECU status that cannot be changed...

Page 62: ... of low or zero voltage e g broken circuit Atm press signal high It is displayed when excessive voltage is detected in the sensor circuit Air temperature sensor Air temp signal low It is displayed when low voltage is detected in the sensor circuit Air temp signal high It is displayed in case of excessive voltage e g broken circuit but freeze frame reads 40 maximum ohm resistance Water temper senso...

Page 63: ...ine does not start if an error is present It switches to MEM when the engine is switched off so it can be deleted even if the fault persists Camshaft signal missing It is displayed almost immediately the engine starts even if the signal is missing It switches to MEM when the engine is switched off so it can be deleted even if the fault persists Front coil Rear coil Fan Error is detected based on r...

Page 64: ...r start up it stays at 5000 rpm The engine starting attempts count that appears in the error frozen parameters is reset Throttle position self learning The ECU self learning procedure for the throttle sensor position and the stepper motor in case the TPS or the stepper motor are changed CO adjustment 1 Adjustment is possible only with PASSWORD authority whenever it is not possible to balance the C...

Page 65: ...ation when the error in question was last detected It cannot be reset data stored in the ECU From the adjustable parameters page it is possible to align the throttle position sensor initialise the ECU i e align the throttle reset the stepper motor and reset the lambda control adaptive parameters initialise the ECU necessary when installing a new ECU Throttle position sensor alignment TPS alignment...

Page 66: ...e the tank on a clean surface with the pump unit facing upward Loosen and remove the eight screws 1 NOTE When reassembling tighten all the screws 1 finger tight observing a cross pattern WARNING When removing the pump unit take care not to damage the tubing and the fuel level sensor Remove the complete pump unit ...

Page 67: ...FUEL SYSTEM 3 17 TUONO 1000 3 2 2 REMOVING THE FUEL LEVEL SENSOR Remove the complete fuel unit Disconnect the connector Loosen and remove the two screws Remove the fuel level sensor ...

Page 68: ... When reassembling replace the tie with a new one of the same size Do not refit the old tie it is no longer useable Do not replace the tie with a screw tie or other type of tie Unfasten the tie 1 Slide the tube out of the filter Unfasten the tie 2 Slide the filter out of the tube WARNING Do not use filters that have already been used Replace the filter with a new one of the same kind ...

Page 69: ...7295 pliers for fitting ties WARNING When reassembling replace the tie with a new one of the same size Do not refit the old tie it is no longer useable Do not replace the tie with a screw tie or other type of tie Unfasten the tie 1 Slide the fuel tube out of the pump Disconnect the electrical connector Disconnect the electrical connector ...

Page 70: ...0 Loosen and remove the three screws Bend the side of the fuel filter and hold it in position NOTE Use compressed air to clean any sediments in the filter mesh direct the jet of air so that the impurities do not penetrate inward ...

Page 71: ...ainted and cannot be set The adjustment screws can be set only when replacing the wire securing bracket 2 completely The two M4x12 screws 3 for securing the throttle valve potentiometer are painted and can be removed only when replacing the sensor Partially remove the fuel tank Remove the air box Disconnect the electrical connectors right injector left injector ...

Page 72: ...0277295 pliers for fitting ties Unfasten the tie 4 Unfasten the tie 5 Slide the tubes out of the throttle unit Disconnect the two accelerator control wires WARNING When reassembling ensure that the two accelerator control wire adjusters are correctly secured to their links and adjust play if necessary ...

Page 73: ...lace the complete throttle unit and the connected fuel tank on a clean surface When reassembling ensure that the delivery fuel line is neither twisted nor in a position in which it can be crushed by other components if damaged or worn it must be replaced the delivery fuel line is positioned so that it reaches the right hand side of the throttle unit passing under it between the two intake flanges ...

Page 74: ...x12 screws 3 Slide the complete accelerator wire securing bracket 4 along with the two bushings 5 and the torsion spring 6 out of the throttle unit Loosen and remove the two M6x16 screws 7 and remove the fuel pressure regulator 8 complete with the O ring Loosen and remove the three M6x25 screws 9 and remove the left injector bracket 10 together with the gasket 11 injector 12 and seal 13 from the t...

Page 75: ...M 3 25 TUONO 1000 Loosen and remove the two M6x25 screws 14 remove the right injector bracket 15 together with the gasket 16 injector 17 and seal 18 NOTE The injector seal 18 can be left in the throttle unit hole ...

Page 76: ... 20 the belt roller 21 the two bushings 22 and the torsion spring 23 Slide the fulcrum pin 24 together with the safety washer 25 out of the hole of the accelerator wire securing bracket and remove the two shaft gaskets 26 together with the torsion spring 27 and the cold starting lever 28 ...

Page 77: ...e intake pressure sensor tubes 2 for clogging Check the throttle valve unit and the wire securing mechanism 3 for any mechanical damage NOTE Synchronise the cylinders when replacing the synchronisation screws 4 or the O rings 5 Loosen the two cylinder synchronisation screws 4 only if there is an air leak When replacing the ball joint linkage 6 unfasten the linkage from the throttle valve control l...

Page 78: ...ngs 12 have been replaced moderately tighten the screws 11 until they are flush with the surface and then loosen by one turn Synchronisation screw pre adjustment 11 1 turn WARNING Precise screw adjustment 11 must be performed with a vacuum gauge Secure the fuel pressure regulator 13 with the two M6x16 screws 14 NOTE Spread a thin layer of grease over the surface of the fulcrum pin 18 Fit the cold ...

Page 79: ...nd belt roller 21 NOTE Spray the spring 20 with temporary lubricant Fit the spring washer 22 NOTE Apply LOCTITE 243 to the nut threading 23 Tighten the M8x1 nut 23 NOTE Apply LOCTITE 243 to the screw threading 25 Secure the accelerator wire securing bracket 24 with the three T E M5x12 screws 25 Fit the throttle valve control lever 26 ...

Page 80: ...torsion spring 4 on the throttle body Fit the throttle valve control lever 2 on the throttle valve axis NOTE Spray the spring 4 with temporary lubricant WARNING Ensure that the ends of the torsion spring 4 are fastened to the throttle body and to the throttle valve control 2 Fit the spring washer NOTE Apply LOCTITE 243 to the nut threading 1 Tighten the M8x1 nut 1 NOTE When reassembly is completed...

Page 81: ...kness gauge 1 measure the minimum value of play between the lever 2 and the contact surface 3 in various points of the throttle body Axial play 0 1 mm 0 0039 in WARNING If the minimum value measured is less than 0 1 mm 0 0039 in replace the entire throttle body With the throttle valves open Repeat the procedure above Axial play 0 15 mm 0 0059 in WARNING If the minimum value measured is less than 0...

Page 82: ...ENGINE 4 1 TUONO 1000 ENGINE 4 ...

Page 83: ...ENGINE 4 2 TUONO 1000 SUMMARY 4 1 ENGINE 3 4 1 1 REMOVING THE ENGINE 3 4 1 2 INSTALLING THE ENGINE 26 4 1 3 TIGHTENING TORQUES 51 ...

Page 84: ...1 1 REMOVING THE ENGINE To remove the engine you will have to remove seat fuel tank and battery first Remove the airbox cover Remove the screws fixing the airbox to the frame Remove the six screws fixing then throttle body to the airbox ...

Page 85: ...ENGINE 4 4 TUONO 1000 Disconnect the bypass tubes to the throttle body and the stepper motor connection Disconnect the oil recovery tank tube ...

Page 86: ...ENGINE 4 5 TUONO 1000 Disconnect the manifold pressure sensor and tubes coming from the throttle body Remove the airbox ...

Page 87: ...ENGINE 4 6 TUONO 1000 Disconnect the coil wiring Disconnect the accelerator control wires Disconnect the throttle potentiometer Disconnect the vacuum tubes on the throttle body ...

Page 88: ...ENGINE 4 7 TUONO 1000 Disconnect the injector connectors Loosen the ties on the intake manifolds ...

Page 89: ...ENGINE 4 8 TUONO 1000 Disconnect the throttle body Plug all openings to avoid entry of impurities Unfasten the ties of the lubrication circuit tubes coming from the oil tank ...

Page 90: ...ENGINE 4 9 TUONO 1000 Disconnect the oil tubes on the crankcase ...

Page 91: ...10 TUONO 1000 Loosen the three fixing screws on the oil tank Remove the oil tank along with the tube coming from the oil cooler Slide the breather tubes out of their housing Remove the oil tube on the crankcase ...

Page 92: ...emove the rear brake fluid reservoir fixing screw and move the reservoir downward keeping it vertical Remove the clamp Remove the coolant breather tube Loosen and remove the two expansion tank fixing screws and remove the expansion tank ...

Page 93: ...NE 4 12 TUONO 1000 Disconnect the connectors Loosen and remove the two fixing screws and remove the voltage regulator Loosen and remove the two fixing screws and remove the voltage regulator mounting plate ...

Page 94: ... that secures the oil tube clamp to the crankcase Disconnect the oil tube from the right hand side Loosen and remove the four oil cooler subframe fixing screws NOTE For the screw on the upper left hand side tighten the internal nut with a spanner ...

Page 95: ...TUONO 1000 Remove the subframe complete with oil coolers Remove the rear brake master cylinder fixing screws Unfasten the clip fixing the master cylinder to the brake lever Disconnect the engine oil pressure sensor ...

Page 96: ...connect the vehicle speed sensor the stop light switch and the lambda sensor connectors Remove the oil cooler lower brackets and move it keeping it vertical Unscrew the starter motor connection Unhook the silencer fixing springs ...

Page 97: ...NO 1000 Loosen the silencer clamp fixing screws Remove the silencers Unhook the fixing spring located between the front cylinder manifold and the exhaust Loosen the four nuts fixing the manifold to the front cylinder ...

Page 98: ...ENGINE 4 17 TUONO 1000 Remove the manifold Remove the seal Unhook the fixing spring located between the rear manifold and the exhaust Slide the lambda sensor wiring out of the frame ...

Page 99: ...th lambda sensor Loosen the four nuts fixing the manifold to the rear cylinder Remove the exhaust manifold remove the seal Disconnect the engine temperature sensor the timing sensor the rpm sensor the side stand safety switch and the generator connectors ...

Page 100: ...ENGINE 4 19 TUONO 1000 ...

Page 101: ...ENGINE 4 20 TUONO 1000 Disconnect the spark plug caps Remove the gear lever ...

Page 102: ...ENGINE 4 21 TUONO 1000 Remove the clutch actuator complete with flange Remove the sprocket cover and the crankcase guide plate Unscrew the sprocket fixing bolt and set aside the seal washer ...

Page 103: ...ENGINE 4 22 TUONO 1000 Remove the sprocket Unfasten the ties and disconnect the coolant tubes on the oil cooler Unscrew the earth connections on the crankcase Unscrew the neutral sensor connection ...

Page 104: ...ve the rear brake lever Remove the lever bracket and the rear brake master cylinder Remove the brake master cylinder bracket Disconnect the vacuum tube on the clutch pneumatic actuator Hold up the engine with an adequate support ...

Page 105: ...ENGINE 4 24 TUONO 1000 Remove the rear screws fixing the engine to the frame Loosen the four screws of the engine front mounts Remove the screws and the spacers located between the frame and the engine ...

Page 106: ...ENGINE 4 25 TUONO 1000 Pull back the adjustment bushings between the engine and the frame Completely lower the engine ...

Page 107: ...ENGINE 4 26 TUONO 1000 4 1 2 INSTALLING THE ENGINE Place the engine on a suitable lower support Lift the engine Position the engine so as to align the rear mounts on the frame Fit the front left spacer ...

Page 108: ...ENGINE 4 27 TUONO 1000 Tighten the two screws in the front left engine mount Fit the left rear spacer and tighten the screws to the specified torque Tighten the left rear screw ...

Page 109: ...the front right spacer Tighten the two screws in the front right mount Tighten the four screws on the left hand side Tighten the upper right bushing to the specified torque Tighten the upper right ring nut to the specified torque ...

Page 110: ...00 Tighten the lower right bushing to the specified torque Tighten the lower right ring nut to the specified torque Tighten the upper right screw Tighten the lower right screw Tighten the four screws on the right hand side ...

Page 111: ...00 Remove the engine lower support Reconnect the vacuum tube to the clutch pneumatic actuator and fasten it with a tie Fit the lever and the rear brake master cylinder bracket and tighten the screws to the specified torque ...

Page 112: ... and tighten the screws to the specified torque Fit the rear brake master cylinder and connect it to the brake lever Tighten the neutral sensor connection Reconnect the earth connection to the crankcase and tighten the screws to the specified torque ...

Page 113: ...ENGINE 4 32 TUONO 1000 Use ties to fasten the coolant tubes to the oil cooler Place the sprocket in the correct position ...

Page 114: ...1000 Tighten the fixing bolt to the specified torque to secure the sprocket in place Fit the sprocket cover and the guide plate and tighten the screws to the specified torque Fit the clutch actuator complete with flange ...

Page 115: ... 4 34 TUONO 1000 Fit the gear lever Insert the spark plug caps in their housing Connect the engine temperature sensor the timing sensor the rpm sensor the side stand safety switch and the generator connectors ...

Page 116: ...ENGINE 4 35 TUONO 1000 ...

Page 117: ...xhaust manifold with the washer Tighten the nuts and stud bolts to the specified torque Fit the exhaust complete with lambda sensor Hook the fixing spring located between the rear manifold and the exhaust Place the lambda sensor wiring on the frame ...

Page 118: ... 4 37 TUONO 1000 Place the exhaust gasket on the front cylinder Fit the manifold on the cylinder stud bolts and on the exhaust Tighten the four nuts fixing the manifold to the cylinder to the specified torque ...

Page 119: ...ENGINE 4 38 TUONO 1000 Hook the fixing spring between the front cylinder manifold and the exhaust Fit the silencers Tighten the silencer clamp fixing screws Hook the silencer fixing springs ...

Page 120: ... 1000 Tighten the starter motor connection Move the oil cooler toward the engine and secure the lower supports Refit the lambda sensor stop light switch and speed sensor connectors Connect the engine oil pressure sensor ...

Page 121: ...UONO 1000 Fasten the clip fixing the master cylinder to the brake lever Tighten the rear brake master cylinder fixing screws Fit the subframe complete with oil coolers Tighten the four screws to the specified torque ...

Page 122: ...pper left hand side tighten the internal nut with a spanner Connect the oil tube from the right hand side Tighten the stud bolt that secures the oil tube clamp to the crankcase Fit the voltage regulator mounting plate and tighten the two fixing screws ...

Page 123: ...ENGINE 4 42 TUONO 1000 Fit the voltage regulator and tighten the two fixing screws Restore all connections Fit the expansion tank and tighten the two fixing screws ...

Page 124: ...ENGINE 4 43 TUONO 1000 Fit the coolant breather tube Fit the clamp Fit the rear brake fluid reservoir and tighten the fixing screw Fit the oil tube on the crankcase ...

Page 125: ...he three oil tank fixing screws Fit a new clamp to the tube coming from the oil cooler and fit the tube into place in the housing Insert the breather tubes in their housing Fit the oil tubes to the engine crankcase and secure in place with new clamps ...

Page 126: ...ENGINE 4 45 TUONO 1000 Remove the plugs from the ducts Fit the throttle body ...

Page 127: ...ENGINE 4 46 TUONO 1000 Fasten the ties on the intake manifolds Connect the injector connectors Insert the vacuum tubes in the throttle body ...

Page 128: ...ENGINE 4 47 TUONO 1000 Connect the throttle position sensor Fit the throttle control wires and adjust play ...

Page 129: ...ENGINE 4 48 TUONO 1000 Connect the coil wiring Fit the airbox Reconnect the manifold pressure sensor and tubes coming from the throttle body ...

Page 130: ...GINE 4 49 TUONO 1000 Disconnect the oil recovery tank tube Disconnect the by pass tubes to the throttle body and the stepper motor connection Tighten the six screws fixing the throttle body to the airbox ...

Page 131: ...ENGINE 4 50 TUONO 1000 Fit the airbox cover Fit the battery the fuel tank and the seat ...

Page 132: ...WINGARM Swingarm pivot ring nut 1 M30x1 5 60 Swingarm pivot adjustment bushing 1 M30x1 5 12 Swingarm pivot nut 1 M20x1 5 90 Calliper carrier retaining pin 1 M12 50 Loctite 243 Chain tightener screw and nut 1 1 M8 Man Rear brake line guide 3 M5 4 Chain guard upper fixing screw 1 M5 4 Chain guard and chain eye mount lower fixing screw 1 M5 5 Chain slider 2 M5 3 Chain eye to chain eye mount upper fix...

Page 133: ... bracket 2 M6 10 Filler neck to coolant radiator 1 M6 20 See RH spoiler front fixing Coolant radiator side brackets to engine mount spacers 2 2 M6 10 20 Coolant radiator to side brackets 2 M6 6 Oil cooler bracket to engine 4 M6 10 Oil coolers to bracket 4 M6 10 Expansion tank to frame 2 M6 10 Expansion tank cap 1 M28x3 6 Tube clamps no 8104097 4 REAR BRAKING SYSTEM Rear brake calliper 2 M8 25 20 R...

Page 134: ...r to seat frame 2 M6 7 RIGHT LEFT SIDE PANELS Side panels to tail guard 2 M5 2 Side panels to tank 2 M5 5 BELLY PAN Complete belly pan to oil cooler bracket and engine spacers 3 M6 7 RIGHT LEFT SIDE COVERS Side covers rear end 2 M6 7 Side covers front end with spoiler spacers 2 M6 10 Right side cover to voltage regulator mount 1 M6 5 RIGHT LEFT RADIATOR FAIRING RH LH radiator fairing to fan peg 2 ...

Page 135: ...CYCLE PARTS 5 1 TUONO 1000 CYCLE PARTS 5 ...

Page 136: ...5 2 CHECKING THE COMPONENTS 65 5 5 3 REMOVING THE SWINGARM BEARINGS 66 5 5 4 REFITTING THE SWINGARM 67 5 5 5 TIGHTENING TORQUES 70 5 6 FRONT WHEEL 71 5 6 1 DIAGRAM 71 5 6 2 REMOVING THE FRONT WHEEL 72 5 6 3 CHECKING THE FRONT WHEEL COMPONENTS 75 5 6 4 REMOVING THE FRONT WHEEL BEARINGS 77 5 6 5 REFITTING THE FRONT WHEEL BEARINGS 78 5 6 6 FITTING THE WHEEL 80 5 7 REAR WHEEL 82 5 7 1 DIAGRAM 82 5 7 2...

Page 137: ...3 TUONO 1000 5 10 CLUTCH 110 5 10 1 BLEEDING THE CLUTCH SYSTEM 110 5 11 CHAIN 111 5 11 1 DRIVE CHAIN 111 5 11 2 INSPECTING THE DRIVE CHAIN SLIDER 113 5 11 3 REMOVING THE CHAIN SLIDER 114 5 11 4 LOWER CHAIN SLIDER 116 ...

Page 138: ...NG THE UPPERWORKS Loosen and remove the two fixing screws 1 and set aside the washers Remove the fairing 2 Unscrew and remove the fixing pin 3 Loosen and remove the fixing screw 4 and set aside the washer Release the quick release fitting 5 and free the tube Remove the fairing 6 ...

Page 139: ... screw 7 Remove the fairing 8 Loosen and remove the two fixing screws 9 and set aside the washers Remove the fairing 10 Loosen and remove the left fixing screw and set aside the washer 11 Loosen and remove the front fixing screw and set aside the washer 12 ...

Page 140: ...emove the fairing 14 Loosen and remove the two fixing screws and set aside the washers 15 Remove the fairing 16 Loosen and remove the two fixing screws 17 and set aside the washers Unscrew and remove the fixing pin 18 Remove the fairing 19 Loosen and remove the fixing screw 20 Remove the fairing 21 ...

Page 141: ...UPPERWORKS Fit the fairing 21 Tighten the fixing screw 20 Fit the fairing 19 Insert and tighten the fixing pin 18 Tighten the two fixing screws 17 Fit the fairing 16 Tighten the two fixing screws 15 Fit the fairing 14 Tighten the right fixing screw 13 ...

Page 142: ...CYCLE PARTS 5 8 TUONO 1000 Tighten the front fixing screw 12 Tighten the left fixing screw 11 Fit the fairing 10 Tighten the two fixing screws 9 Fit the fairing 8 Tighten the fixing screw 7 ...

Page 143: ...CYCLE PARTS 5 9 TUONO 1000 Fit the fairing 6 Fit the tube in the quick fitting coupling 5 Tighten the fixing screw 4 Tighten the fixing pin 3 Fit the fairing 2 Tighten the two fixing screws 1 ...

Page 144: ...ly pan to oil cooler bracket and engine spacers 3 M6 7 RIGHT LEFT SIDE COVERS Side covers rear end 2 M6 7 Side covers front end with spoiler spacers 2 M6 10 Right side cover to voltage regulator mount 1 M6 5 RIGHT LEFT RADIATOR FAIRING RH LH radiator fairing to fan peg 2 SWp 3 9 1 RIGHT LEFT SPOILER Spoiler rear end to spacer 2 M6 7 Spoiler front end to coolant radiator 2 M6 7 OIL TANK COVER Cover...

Page 145: ...ing 5 Spring 6 Complete preload tube 7 Spacer 8 Washer 9 Complete damper rod 10 Washer 11 Ring 12 Complete sleeve plug 13 O ring 14 O ring 15 O ring 16 Stop ring 17 M8x40 flanged screw 18 Right leg wheel carrier 19 Left leg wheel carrier 20 Dust seal 21 Circlip 22 Oil seal 23 Ring 24 Bushing 25 Sliding bushing 26 Special washer 27 M10x1 5 screw ...

Page 146: ... PARTS 5 12 TUONO 1000 5 2 2 REMOVING THE FORK LEGS Support the front end of the vehicle Loosen the front mudguard screws and remove it Loosen the front callipers fixing screws and slide them out of the disc ...

Page 147: ...CYCLE PARTS 5 13 TUONO 1000 Remove the wheel shaft nut Set aside the washer ...

Page 148: ...wheel shaft pinch bolts Lightly tap the wheel shaft with a rubber mallet until the holes on the opposite side are uncovered Remove the wheel shaft using a screwdriver inside the shaft holes During this operation support and remove the wheel ...

Page 149: ...CYCLE PARTS 5 15 TUONO 1000 Support the fork and loosen the top and bottom yoke screws Fit the fork leg ...

Page 150: ...G THE FORK LEGS Fit the fork leg Adjust sleeve sliding and tighten the screws on the fork yokes to the specified torque Fit the front wheel and insert the wheel shaft in its housing Tighten the clamp screws nut side to secure the wheel shaft ...

Page 151: ...000 Fit the washer and tighten the wheel shaft nut to the specified torque Work the fork to ensure that the fork legs are aligned Working on both sides tighten the clamp screws securing the wheel shaft to the specified torque ...

Page 152: ... PARTS 5 18 TUONO 1000 Fit the callipers on the disc Fit the brake callipers and tighten the screws to the specified torque WARNING After installing the brake callipers pull the front brake lever a few times ...

Page 153: ... 5 19 TUONO 1000 5 2 4 REPLACING FORK FLUID Clamp the sleeve in a vice with the specified tool Set the spring preload to its minimum Unscrew the sleeve upper plug Clamp the fork foot with care to avoid damaging it ...

Page 154: ...cified tool on the spring joint Push the tool downward to compress the spring and then fit the tool spacer under the cartridge lock nut Loosen the plug by placing the key in the provided opening and loosening the nut Remove the complete plug ...

Page 155: ...CYCLE PARTS 5 21 TUONO 1000 Remove the spacer and the washer Press downward against spring force and slide out the spacer Slide out the spring joint Empty the oil into a container and remove the spring ...

Page 156: ... 2 5 FILLING THE FRONT FORK FLUID Fill the fork so the air bubbles trapped inside are released Fit the spring joint Fit the specific tool on the spring joint so the cartridge rod is secured in position Fit the spacer and the washer ...

Page 157: ...CYCLE PARTS 5 23 TUONO 1000 Tighten the upper plug on the cartridge rod Clamp the sleeve in a vice with the specified tool ...

Page 158: ...CYCLE PARTS 5 24 TUONO 1000 Tighten the upper plug to the specified torque ...

Page 159: ...TUONO 1000 5 2 6 REPLACING THE OIL SEAL DUST SEAL Clamp the sleeve in a vice with the specified tool Set the spring preload to its minimum Unscrew the sleeve upper plug Clamp the fork foot with care to avoid damaging it ...

Page 160: ...cified tool on the spring joint Push the tool downward to compress the spring and then fit the tool spacer under the cartridge lock nut Loosen the plug by placing the key in the provided opening and loosening the nut Remove the complete plug ...

Page 161: ...CYCLE PARTS 5 27 TUONO 1000 Remove the spacer and the washer Press downward against spring force and slide out the spacer Slide out the spring joint Empty the oil into a container and remove the spring ...

Page 162: ...CYCLE PARTS 5 28 TUONO 1000 Remove the spacer and the washer Loosen the cartridge fixing screw on the fork foot Set aside the centring bushing ...

Page 163: ...l using a screwdriver for leverage When doing this take care not to damage the edge of the sleeve Remove the circlip Remove the sleeve from the slider using the sleeve as a stop Remove the bushing the movable bushing the ring and the oil seal from the slider ...

Page 164: ...CYCLE PARTS 5 30 TUONO 1000 Remove the ring and the dust seal ...

Page 165: ...CYCLE PARTS 5 31 TUONO 1000 ...

Page 166: ... SEAL DUST SEAL Clamp the leg in a vice with care to avoid damaging its surfaces Protect the ends of the leg with adhesive tape Lubricate the sliding edges with fork fluid or seal grease Fit the dust seal the stop ring and the sealer ring on the slider ...

Page 167: ...CYCLE PARTS 5 33 TUONO 1000 Ensure that the stamped side of the sealer ring is facing the dust seal Proceed to fit the ring the movable bushing and after having removed the tape the fixed bushing ...

Page 168: ...sleeve on the leg and using the specific tool fit the oil seal in position Insert the stop ring in its housing Fit the dust seal with the specific tool Fit the centring bushing on the cartridge and place the complete assembly in the fork ...

Page 169: ...CYCLE PARTS 5 35 TUONO 1000 Tighten the cartridge fixing screw on the fork foot to the specified torque Fit the lower spacer and the washer Fit the fork spring ...

Page 170: ...5 36 TUONO 1000 Fill the fork so the air bubbles trapped inside are released Fit the spring joint Fit the specific tool on the spring joint so the cartridge rod is secured in position Fit the spacer and the washer ...

Page 171: ...CYCLE PARTS 5 37 TUONO 1000 Tighten the upper plug on the cartridge rod Clamp the sleeve in a vice with the specified tool ...

Page 172: ...CYCLE PARTS 5 38 TUONO 1000 Tighten the upper plug to the specified torque ...

Page 173: ...d the service limit Buckling limit 0 2 mm 0 008 in SLEEVE Inspect for damage and or cracking Replace if damaged DANGER NEVER attempt to straighten a buckled stanchion as this would weaken the overall structure leading to a dangerous riding condition SPRING Check spring condition and ensure that the length is within the specified limits If the length does not correspond replace the spring Minimum l...

Page 174: ...e oil level the sleeve must be perfectly vertical The oil level must be the same in both legs The standard adjustment of the fork meets most conditions of high and low speed riding whether the vehicle is travelling with a full load or not It is however possible to customise the adjustment depending on how the vehicle is used WARNING When proceeding with the adjustment always start from the stiffes...

Page 175: ...ojection notches Leg projection A from upper yoke excluding plug 1 projection notch clockwise anticlockwise For this type of adjustment please contact exclusively an aprilia Authorised Dealer NOTE Öhlins forks available on request OPT Öhlins front fork OPT The standard adjustment of the fork meets most conditions of high and low speed riding whether the vehicle is travelling with a full load or no...

Page 176: ...pression damping adjustment screw 2 from completely closed open 12 turns Spring preload nut 3 from completely open close 8 turns Leg projection A from upper yoke excluding plug 4 projection notches clockwise anticlockwise For this type of adjustment please contact exclusively an aprilia Authorised Dealer ...

Page 177: ...M6 10 LIGHTS INSTRUMENT PANEL Rear turn indicators 2 M4 1 Front turn indicators 2 M6 4 Tail light to tail guard 4 M5 2 20 Headlight to conveyor 2 M5 2 Headlight to fairing front piece 4 M5 2 Instrument panel 3 SWP5x14 3 AIR BOX Air box cover 7 SWP5x20 3 20 Air box to throttle body 6 M6 5 20 Intake funnels 4 SWP 3 9 1 20 MAP sensor mount 1 SWP5x20 2 20 Filter frame 2 SWP5x20 2 Conveyor to frame 4 M...

Page 178: ... safety plate 6 Top yoke fixing bushing 7 Dust seal 8 Dust seal 9 Headstock plug washer 10 Axial ball bearing 11 Steering damper 12 Front damper mount 13 M6x25 flanged screw 14 M8x35 TCEI screw 15 Handlebar lower U bolt 16 Bushing 17 Bushing 18 TE pf M6x80 screw 19 Curved spring washer 20 M8x45 TCEI screw 21 Washer 22 Wire guide ...

Page 179: ...ARTS 5 45 TUONO 1000 5 3 2 CHECKING PLAY Steering bearings and steering play Place the vehicle on the central support stand Shake the fork in the direction of travel If play is noticed proceed with adjustment ...

Page 180: ... stand Remove the handlebar taking special care not to spill oil from the clutch reservoir or from the front brake fluid reservoir Loosen and remove the headstock upper nut and set aside the washer Loosen the fork leg fixing screws on the upper yoke Slide out the fork upper yoke moving it toward the instrument panel ...

Page 181: ...CYCLE PARTS 5 47 TUONO 1000 Straighten the safety washer on the headstock Loosen the upper ring nut and remove the safety washer ...

Page 182: ...48 TUONO 1000 Adjust the steering bearing preload by tightening the lower ring nut to the specified torque Fit the safety washer Fit the upper ring nut and tighten so the grooves correspond to the safety washer tabs ...

Page 183: ...49 TUONO 1000 Rivet the tabs on the upper ring nut Fit the upper fork yoke Tighten the upper bolt on the headstock to the specified torque Tighten the fork leg fixing screws on the upper yoke to the specified torque ...

Page 184: ...CYCLE PARTS 5 50 TUONO 1000 Fit the handlebar Fit the U bolt Tighten the four U bolt fixing screws to the specified torque ...

Page 185: ...s Showa 2 2 M8 22 Front fork clamps Öhlins 2 2 M6 12 STEERING DAMPER Steering damper to frame 1 M6 10 Loctite 243 Steering damper to lower fork yoke 1 M6 10 HEADLIGHTS INSTRUMENT PANEL Rear turn indicators 2 M4 1 Front turn indicators 2 M6 4 Tail light to tail guard 4 M5 2 20 Headlight to conveyor 2 M5 2 Headlight to fairing front piece 4 M5 2 Instrument panel 3 SWP5x14 3 AIR BOX Air box cover 7 S...

Page 186: ... 1 M6 10 HANDLEBAR AND CONTROLS Upper U bolt to handlebar mounts 4 M8 25 Handlebar mounts to fork upper yoke for workshop manual only 2 M10 30 Loctite 243 Anti vibration weights 2 M6 10 Anti vibration weight end caps 2 M18x1 35 LH dimmer switch 1 M5x1 1 5 RH dimmer switch 1 M4 1 5 Front brake master cylinder 2 M6 8 Clutch master cylinder 2 M6 8 MUDGUARDS Front mudguard 4 M5 5 ...

Page 187: ...SPENSION 5 4 1 DIAGRAM Key 1 Shock absorber 2 Double connecting rod 3 Roller case 4 D18x24x3 oil seal 5 Pin L 36 6 Screw 7 T bushing 8 M10 flanged self locking nut 9 Complete single connecting rod 10 M10x59 TCEI screw 11 M10x61 flanged screw ...

Page 188: ...le loosen the upper screw 1 but do not remove it and remove the nut Working from the left hand side of the vehicle loosen the lower screw 2 but do not remove it and remove the nut Operate the A frame to raise the motorcycle just enough to remove load from the swingarm but do not lift the motorcycle off the ground Remove the upper screw 1 Remove the lower screw 2 ...

Page 189: ...CYCLE PARTS 5 55 TUONO 1000 Remove the rear shock absorber 3 from between swingarm and rear subframe ...

Page 190: ...ld be replaced WARNING Apply grease to the rollers SEALS Check that all seals are intact replace them if they are damaged or worn SHOCK ABSORBER Check that the shock absorber shows no signs of oil leaks and that its stroke is smooth and progressive Replace if necessary REAR SUSPENSION Standard adjustment Spring length preloaded B 147 mm 5 79 in Rebound adjustment screw 1 from completely closed ope...

Page 191: ...age conditions When you increase spring preload you should also increase rebound damping to avoid sudden jerks when riding WARNING OPT Do not loosen the screw 8 or disturb the membrane located underneath or the resulting nitrogen loss will impair shock absorber operation making the motorcycle unsafe to ride Öhlins shock absorber Rear suspension Standard adjustment Shock absorber centre distance A ...

Page 192: ...hock absorber 3 between swingarm and rear subframe Fit the lower screw 2 Operate the A frame until aligning the frame hole with the rear suspension upper mounting point Fit the upper screw 1 Working from the right hand side of the vehicle fit the nut 2 to the lower screw and tighten ...

Page 193: ...CYCLE PARTS 5 59 TUONO 1000 Working from the left hand side of the vehicle fit the nut 1 to the upper screw and tighten Release the motorcycle from the A frame and remove the slings ...

Page 194: ...m the opposite side 2 Loosen and remove the nut 3 Remove the screw from the opposite side 4 Loosen and remove the nut 5 Remove the screw from the opposite side 6 Remove the complete suspension connecting rod unit 7 NOTE When reassembling grease the connecting rod pivot points ensure that all the parts are correctly positioned and check repeatedly that all joints move freely ...

Page 195: ...orque wrench and LOCTITE where specified DESCRIPTION QUANTITY NUT BOLT TORQUE Nm TOL NOTE REAR SHOCK ABSORBER Shock absorber to frame 1 M10 50 REAR SUSPENSION CONNECTING RODS Single connecting rod to frame 1 M10 50 Single to double connecting rod 1 M10 50 Double connecting rod to swingarm 1 M10 50 Double connecting rod to shock absorber 1 M10 50 ...

Page 196: ...the rear support stand OPT so it is in work position fastened to the two swingarm pegs Remove the exhaust system Loosen and remove the three guard fixing screws and set aside the washers Carefully rest the support plate on the ground on its side complete with the brake calliper and the speed sensor connected to the tube and to the wire respectively WARNING Do not pull the rear brake lever when the...

Page 197: ...g on the left hand side loosen and remove the shock absorber lower nut Remove the screw from the opposite side Loosen and remove the nut and set aside the washer NOTE Use the special tool OPT aprilia part 8140191 tool for tightening swingarm pivot and supporting engine Use the box spanner to loosen and remove the ring nut 1 on the right hand side of the vehicle ...

Page 198: ...to prevent it from lowering and keep it in position Place the support under the front end of the swingarm Support the front end of the swingarm Slide the swingarm pivot 2 out from the right hand side WARNING When removing the swingarm ensure that the drive chain does not tangle up Support the front of the swingarm and be prepared to guide its movement Using the rear support stand slide the swingar...

Page 199: ...ngs of the same type RADIAL AND AXIAL PLAY CHECK Check radial and axial play Axial play minimum axial play is accepted Radial play none If one or both bearings do not meet the specifications replace both swingarm bearings DANGER Always replace both bearings Always replace bearings with bearings of the same type SWINGARM SEALS Check that all seals are intact replace them if they are damaged or worn...

Page 200: ...r WARNING After removing the bearings check to see if they should be replaced Remove the inner spacer 7 and set aside the two O rings 8 Remove the inner spacer 9 Remove the gaskets 10 Remove the two roller bearings with an extractor 11 WARNING After removing the bearings check to see if they should be replaced Clean the bearing housing thoroughly NOTE Wash all components with clean detergent WARNI...

Page 201: ...using the rear support stand OPT NOTE Shim the resting surface of the rear support stand OPT so it is in work position fastened to the two swingarm pegs Support the front end of the swingarm position it so that the holes are aligned and simultaneously insert the pivot completely 2 NOTE Ensure that the hexagonal area of the pivot head 2 is correctly inserted in the hexagonal housing inside the adju...

Page 202: ... ring nut with a box spanner 1 Tighten the nut Remove the adhesive tape and free the chain Fit the chain on the transmission sprocket NOTE Apply LOCTITE Anti Seize to the inner teeth of the transmission sprocket Fit the sprocket complete with chain on the shaft NOTE Apply LOCTITE 243 to the screw threading Insert the washer on the screw Tighten the screw ...

Page 203: ...ight hand side insert the double connecting rod swingarm screw Tighten the nut on the opposite side Fit the support plate complete with brake calliper and speed sensor Tighten the three guard fixing screws complete with washers Fit the sprocket cover and tighten the three screws Fit the rear wheel and the exhaust system Adjust the drive chain tension ...

Page 204: ... fixing screw 1 M5 5 Chain slider 2 M5 3 Chain eye to chain eye mount upper fixing nut 1 M5 nut 5 Rear stand bushing 2 M6 10 Chain eye fixing nut 1 M6 nut 10 REAR SHOCK ABSORBER Shock absorber to frame 1 M10 50 REAR SUSPENSION CONNECTING RODS Single connecting rod to frame 1 M10 50 Single to double connecting rod 1 M10 50 Double connecting rod to swingarm 1 M10 50 Double connecting rod to shock ab...

Page 205: ... Key 1 Naked blue front wheel 2 Tubeless tyre valve 3 Internal spacer 4 6005 2rs1 bearing 5 30x47x7 seal 6 Circlip 7 External spacer 8 Front brake disc 9 25 2x36x1 washer 10 Wheel shaft nut 11 M8x20 flanged screw 12 Front wheel shaft 13 120 70 ZR17 front tyre ...

Page 206: ...PARTS 5 72 TUONO 1000 5 6 2 REMOVING THE FRONT WHEEL Support the front end of the vehicle Loosen the front mudguard screws and remove it Loosen the front calliper fixing screws and slide them out of the disc ...

Page 207: ...CYCLE PARTS 5 73 TUONO 1000 Remove the wheel shaft nut Set aside the washer ...

Page 208: ...wheel shaft pinch bolts Lightly tap the wheel shaft with a rubber mallet until the holes on the opposite side are uncovered Remove the wheel shaft using a screwdriver inside the shaft holes During this operation support and remove the wheel ...

Page 209: ...gs of the same type RADIAL AND AXIAL PLAY CHECK Check radial and axial play Axial play minimum axial play is accepted Radial play none If one or both bearings do not meet the specifications replace both wheel bearings DANGER Always replace both bearings Always replace bearings with bearings of the same type FRONT WHEEL SEALS Check that all seals are intact replace them if they are damaged or worn ...

Page 210: ... axial B eccentricity of the rim 2 does not exceed the specified limit Excess eccentricity is usually caused by worn or damaged bearings If after the bearings have been replaced the value is not within the specified limit replace the rim 2 Maximum radial and axial eccentricity 2 mm 0 0079 in ...

Page 211: ... the wheel The edges of the spacer 4 feature slots A to allow the passage of the extractor teeth NOTE Use the special tool OPT aprilia part 8140180 bearing extractor Remove the right bearing with the extractor 5 Set aside the inner spacer 4 Work on the left hand side of the wheel Remove the seal 2 NOTE Use the special tool OPT aprilia part 8140180 bearing extractor Remove the left bearing with the...

Page 212: ... hand side of the wheel Fit the spacer 4 NOTE Use the special tool OPT aprilia part 8140180 bearing extractor Insert the left bearing 6 using the drift NOTE Complete insertion of the left bearing 6 will couple the following components right bearing 5 spacer 4 left bearing 6 WARNING Once it is home against the right bearing 5 do not push further to avoid forcing the circlip 3 NOTE Once the left bea...

Page 213: ...CYCLE PARTS 5 79 TUONO 1000 ...

Page 214: ...EL Fit the front wheel and insert the wheel shaft in its housing Tighten the clamp screws nut side to secure the wheel shaft Fit the washer and tighten the wheel shaft nut to the specified torque Work the fork to ensure that the fork legs are aligned ...

Page 215: ...ighten the clamp screws securing the wheel shaft to the specified torque Fit the callipers on the disc Fit the brake callipers and tighten the screws to the specified torque WARNING After fitting the brake callipers pull the front brake lever repeatedly ...

Page 216: ...ration damper seal 7 Tubeless tyre valve 8 Rear wheel spacer 9 Retainer 10 M10 self locking nut 11 Complete rear chain sprocket holder 12 Rear wheel shaft 13 M25x1 5 wheel shaft nut 14 25 2x36x1 washer 15 30x52x7 seal 16 Internal spacer 17 Circlip 18 10x20 pin 19 6205 2rs1 bearing 20 M10x30 TCEI screw 21 38x52x7 seal 22 Retaining ring for 55Ø hole 23 30x55x13 bearing 24 Vibration damper spacer 25 ...

Page 217: ...CLE PARTS 5 83 TUONO 1000 5 7 2 REMOVING THE REAR WHEEL Place the vehicle on the rear support stand Loosen and remove the wheel shaft nut Set aside the abutment washer and the left chain tightener slider ...

Page 218: ...shaft so the head comes out of its housing Bring the wheel forward and free the drive chain from the rear sprocket Slide the wheel shaft out together with the right chain tightener slider Remove the complete wheel freeing the disc from the brake calliper ...

Page 219: ...unit Use both hands B to remove the final drive unit parallel to the wheel shaft working from the external diameter of the sprocket 3 REASSEMBLY NOTE Fit the final drive unit parallel to the wheel shaft and place the vibration damper seals 5 in their housing on the vibration damper holder 2 Use both hands C to fit the final drive unit in the vibration damper holder from the external diameter of th...

Page 220: ...CYCLE PARTS 5 86 TUONO 1000 ...

Page 221: ...ecifications replace both wheel bearings DANGER Always replace both bearings Always replace bearings with bearings of the same type REAR WHEEL SEALS Check that all seals are intact replace them if they are damaged or worn DANGER Always replace both seals Always replace seals with seals of the same type REAR WHEEL SHAFT Using a dial gauge check the eccentricity of the wheel shaft 1 If eccentricity ...

Page 222: ...axial play Axial play minimum axial play is accepted Radial play none If one or both bearings do not meet the specifications Replace both final drive unit bearings DANGER Always replace both bearings Always replace bearings with bearings of the same type VIBRATION DAMPER Check that the vibration damper seals 5 are not damaged and or excessively worn To perform the check Fit the complete final driv...

Page 223: ...ROCKET Check the condition of the sprocket teeth 7 In case of excessive wear replace the rear sprocket WARNING To avoid premature wear of new components the rear sprocket the front sprocket and the drive chain must be replaced as a group ...

Page 224: ...ide of the wheel The edges of the spacer 4 feature slots A to allow the passage of the extractor teeth NOTE Use the special tool OPT aprilia part 8140180 bearing extractor Remove the right bearing with the extractor 5 Set aside the inner spacer 4 Work on the left hand side of the wheel NOTE Use the special tool OPT aprilia part 8140180 bearing extractor Remove the left bearing with the extractor 6...

Page 225: ...eel Work on the left hand side of the wheel Fit the spacer 4 NOTE Use the special tool OPT aprilia part 8140180 bearing extractor Insert the left bearing 6 using the drift NOTE Complete insertion of the left bearing 6 will couple the following components right bearing 5 spacer 4 left bearing 6 WARNING Once it is against the right bearing 5 do not push further to avoid forcing the circlip 3 NOTE On...

Page 226: ...CYCLE PARTS 5 92 TUONO 1000 ...

Page 227: ... the circlip 3 NOTE The circlip 3 is fitted only on the left side of the final drive unit NOTE Use the special tool OPT aprilia part 8140180 bearing extractor Remove the left bearing with the extractor 4 Set aside the inner spacer 5 Remove the right bearing with the extractor 6 Set aside the right spacer 7 Clean the inner part of the hub thoroughly NOTE Wash all components with clean detergent ...

Page 228: ... is fully home against the abutment Y Fit the inner spacer 5 Insert the left bearing 4 using the drift NOTE Complete insertion of the left bearing 4 will couple the following components right bearing 6 inner spacer 5 left bearing 4 Fit the circlip 3 NOTE The circlip 3 is fitted only on the left side of the final drive unit Fit a new seal 2 Fit the left spacer 1 with the larger diameter facing the ...

Page 229: ...CLE PARTS 5 95 TUONO 1000 5 7 9 REMOVING THE VIBRATION DAMPER SEALS Remove the final drive unit NOTE The vibration damper seals are fitted on the vibration damper holder Remove all vibration damper seals ...

Page 230: ...e self locking nuts 3 WARNING Do not fit the final drive unit 6 on the wheel to tighten the self locking nuts WARNING To protect the rear sprocket fit wooden or aluminium protections on the vice grips Clamp only the rear sprocket in the vice do not clamp any other components of the final drive group Clamp the rear sprocket in the vice NOTE To avoid possible deformation and or imperfect mating tigh...

Page 231: ...eel shaft together with the right chain guide slider on the swingarm Fit the rear wheel and insert the wheel shaft in its housing Bring the wheel forward and fit the drive chain on the rear sprocket Fit the left chain tightener slider and the abutment washer on the shaft ...

Page 232: ...CYCLE PARTS 5 98 TUONO 1000 Manually tighten the nut Check the chain tension Tighten the fixing nut to the specified torque ...

Page 233: ...8 Man Rear brake line guide 3 M5 4 Chain guard upper fixing screw 1 M5 4 Chain guard and chain eye mount lower fixing screw 1 M5 5 Chain slider 2 M5 3 Chain eye to chain eye mount upper fixing nut 1 M5 nut 5 Rear stand bushing 2 M6 10 Chain eye fixing nut 1 M6 nut 10 REAR WHEEL Rear chain sprocket to sprocket carrier 5 M10 50 Rear wheel shaft nut 1 M25x1 5 120 REAR BRAKING SYSTEM Rear brake callip...

Page 234: ...e callipers Replacing the pads of only one front calliper would compromise the stability and safety of the vehicle potentially resulting in danger for people things and the vehicle itself NOTE The following procedure refers to a single calliper but applies to both Loosen and remove the two brake calliper fixing screws 1 Remove the front brake calliper from the disc Press on the safety spring 2 and...

Page 235: ...pring 2 Press on the safety spring 2 and simultaneously insert the pin from the inside 3 Release the safety spring 2 and hook it correctly on the pin 3 DANGER When it is released the safety spring 2 must secure the pin 3 by entering the housings If positioned correctly the pin 3 will not slip out check this condition Fit the front brake calliper on the disc Manually tighten the two screws complete...

Page 236: ...pplies to both Check disc wear by measuring the minimum thickness in various points with a micrometer If the minimum thickness is lower than the minimum value even if only in one point replace the disc Minimum disc thickness value 4 mm 0 16 in Using a dial gauge check that the disc maximum oscillation does not exceed tolerance if so replace it Disc oscillation tolerance 0 3 mm 0 012 in ...

Page 237: ... we recommend the use of a pneumatic screw gun which will resist the strength of the LOCTITE 243 Loosen and remove the six brake disc screws 1 WARNING When refitting apply LOCTITE 243 to the thread of the brake disc screw 1 NOTE When refitting fit all the screws 1 manually and tighten them observing a cross pattern in the following order A B C D E F Remove the brake disc 2 ...

Page 238: ...ng the bleeding procedure Connect the tube to the brake master cylinder bleed valve Pull the lever and slightly open the bleed valve on the master cylinder to release the air Close the bleed valve before reaching the end of stroke with the lever and repeat the procedure until all the air is released Working from both sides connect the tube to the brake calliper bleed valve ...

Page 239: ...r cylinder REAR BRAKE NOTE Make sure to have a flexible tube and a container of adequate size ready at hand before beginning the bleeding procedure Remove the fairing see DISASSEMBLING THE UPPERWORKS Connect the tube to the brake master cylinder bleed valve Pull the lever and slightly open the bleed valve on the master cylinder to release the air Close the bleed valve before reaching the end of st...

Page 240: ...n the bleed valve on the calliper you wish to bleed to release the air Close the bleed valve before reaching the end of stroke with the lever and repeat the procedure until all the air is released As a precaution repeat the bleed procedure on the brake master cylinder ...

Page 241: ...ads 4 and collect the noise dampening plates WARNING Do not pull the brake lever when the pads are not in place or the calliper pistons might come out of their housing thus causing brake fluid leakage Replace the anti vibration plates if worn WARNING When refitting the anti vibration plates make sure the arrows point in the direction of travel Fit the two new pads together with the anti vibration ...

Page 242: ...easuring the minimum thickness in various points with a micrometer If the minimum thickness is lower than the minimum value even if only in one point replace the disc Minimum disc thickness value 4 mm 0 16 in Using a dial gauge check that the disc maximum oscillation does not exceed tolerance if so replace it Disc oscillation tolerance 0 3 mm 0 012 in ...

Page 243: ...neumatic screw gun which will resist the strength of the LOCTITE 243 Loosen and remove the five brake disc screws 1 WARNING When refitting apply LOCTITE 243 to the thread of the brake disc screw NOTE When refitting fit all the screws manually and tighten them observing a cross pattern in the following order A B C D E Remove the brake disc 2 ...

Page 244: ...uate size ready at hand before beginning the bleeding procedure Connect the tube to the clutch control cylinder bleed valve Pull the lever and slightly open the bleed valve on the slave cylinder to release the air Close the bleed valve before reaching the end of stroke with the lever and repeat the procedure until all the air is released ...

Page 245: ...in an intermediate point of the lower length of chain between the front and rear sprockets is about 25 mm 0 98 in Move the vehicle forward to check vertical oscillation of the chain in other positions play must remain constant in all phases of wheel rotation ADJUSTMENT NOTE To adjust the chain use the rear support stand OPT If the check determines that chain tension adjustment is necessary Place t...

Page 246: ...e seals are damaged or missing replace the entire chain assembly front and rear sprockets and chain Lubricate the chain frequently especially dry or rusty parts Flattened or seized links must be lubricated and restored to working condition CLEANING AND LUBRICATION WARNING The drive chain is fitted with seals between the links to prevent grease from coming out Take special care when adjusting lubri...

Page 247: ...ARTS 5 113 TUONO 1000 5 11 2 INSPECTING THE DRIVE CHAIN SLIDER Place the vehicle on the stand Ensure that the slider 1 is not worn or damaged replace it with a new one if necessary Check for chain guide wear 2 ...

Page 248: ...ver Slacken chain tension Loosen and remove the sprocket fixing screw and set aside the washers NOTE When reassembling apply LOCTITE Anti Seize to the inner teeth of the drive sprocket and LOCTITE 243 to the screw threading Loosen and remove the two screws from the rider left footpeg guard Loosen and remove the chain slider upper fixing screw and set aside the washer ...

Page 249: ... 5 115 TUONO 1000 Loosen and remove the chain slider lower fixing screw and set aside the washer Slide the lower part of the chain slider out from the front Remove the chain slider by sliding it out from the rear ...

Page 250: ...00 5 11 4 LOWER CHAIN SLIDER NOTE When checking for wear the slider must be removed Loosen and remove the two screws Remove the lower chain slider CHECKING WEAR Check the wear of the chain slider Minimum thickness 2 mm 0 079 in ...

Page 251: ...COOLING SYSTEM 6 1 TUONO 1000 COOLING SYSTEM 6 ...

Page 252: ...COOLING SYSTEM 6 2 TUONO 1000 SUMMARY 6 1 COOLING SYSTEM 3 6 1 1 DIAGRAM 3 6 1 2 FILLING THE COOLING SYSTEM 4 ...

Page 253: ...COOLING SYSTEM 6 3 TUONO 1000 6 1 COOLING SYSTEM 6 1 1 DIAGRAM Key 1 Cooler 2 Solenoid valves 3 Expansion tank 4 Oil filler 5 Three way thermostatic valve 6 Three way manifold ...

Page 254: ...ler plug Pour approximately 2 litres 3 6 pt of coolant in the filler When the coolant starts to come out of the breather screw on the radiator tighten the plug to the specified torque To complete the system filling procedure continue to pour the fluid until it reaches the upper rim of the oil filler Unscrew the expansion tank plug and pour the remaining 0 2 litres 0 36 pt of fluid until the level ...

Page 255: ...t the engine for approximately 30 seconds with the filler plug open Turn off the engine and pour some coolant in the filler To complete the system filling procedure continue to pour the fluid until it reaches the upper rim of the filler Start the engine and bring it to operating temperature the electric fans must run at least 2 times turn it off and wait for it to cool down approximately 12 hours ...

Page 256: ...CYCLE PARTS 7 1 TUONO 1000 CYCLE PARTS 7 ...

Page 257: ...EM 3 7 1 1 LOCATION OF THE COMPONENTS 3 7 1 2 ELECTRIC PARTS INSPECTION TABLE 5 7 1 3 CAN LINE 14 7 1 4 IMMOBILIZER 16 7 1 5 LAMBDA SENSOR 18 7 1 6 RECOVERY FUNCTION 19 7 1 7 ENGINE RPM LIMITATION CONDITION 20 7 1 8 NEW MAPPING 21 7 1 9 WIRING DIAGRAM 22 ...

Page 258: ...CYCLE PARTS 7 3 TUONO 1000 7 1 ELECTRIC SYSTEM 7 1 1 LOCATION OF THE COMPONENTS ...

Page 259: ...nsor 6 Bank angle sensor 7 Vehicle speed sensor 8 Injector 9 Ignition coils 10 Throttle position sensor TPS 11 Immobilizer antenna 12 Starter motor 13 Stepper motor 14 Generator 15 Recharge voltage 16 Fuel pump 17 Fuel reserve sensor 18 Control unit 19 Headlight 20 Tail light 21 Auxiliary fuses 22 Main fuses 23 Intake pressure sensor ...

Page 260: ...CYCLE PARTS 7 5 TUONO 1000 7 1 2 ELECTRIC PARTS INSPECTION TABLE ...

Page 261: ...een 12 8 and 14 2 Ω measured across pins 1 and 2 at 20 C 68 F Power voltage 12 V 3 CAMSHAFT SENSOR Hall sensor Fitted in the front cylinder head The sensor allows the control unit to recognise the precise sequence of each cylinder by resetting the inner counter during the ignition asynchronous stage 12V power across pins 3c and 3a Square wave output with a pulse every two rpm measured across pins ...

Page 262: ...ED SENSOR Hall sensor with square wave output at 5 pulses rev power voltage 11 12V measured across pins 1 and 3 low signal when sensor is facing screw head measured across pins 2 and 3 8 INJECTOR resistance between 13 8 and 15 2 Ω Power supply 12 V The push button signal output by the ECU activates an electromagnet attracting an armature and causing fuel injection by opening the injector calibrate...

Page 263: ...inding between 0 40 and 1 15 Ω measured across pins 9d and 9e 10 THROTTLE POSITION SENSOR TPS mechanically coupled to the throttle so that its output voltage depends on throttle position 4 5 to 5 5V power measured across pins 10a and 10c Resistance across VC 10a and E2 10c 2 87 5 33 KΩ Resistance across VTA 10b and E2 10c throttle open 2 87 8 41 KΩ Resistance across VTA 10b and E2 10c throttle clo...

Page 264: ...power the engine to help start up procedure and correct fuel feeding with cold engine When the engine has reached operating temperature the stepper motor will be partially closed 14 GENERATOR three phase generator winding resistance 0 4 Ω output voltage 75 VAC measured with the generator disconnected from the electric system and the engine at 4000 rpm 15 RECHARGE VOLTAGE 13 8 V measured at battery...

Page 265: ...t 3 9 A 17 FUEL RESERVE SENSOR There is no fuel level indicator it is simply a reserve warning light that comes on when level goes below 3 7 litres 30 seconds after fuel is no longer reaching the sensor it starts conducting and the light comes on ...

Page 266: ...a 18 Atmospheric pressure sensor signal Analogue input 19 Rpm sensor signal earth Power supply 20 Timing sensor earth Power supply 21 Air temperature sensor signal Power supply 22 n a 23 n a 24 Throttle Position Sensor signal Analogue input 25 Throttle Position Sensor power supply earth Power supply 26 n a 27 Water temperature sensor signal earth Power supply 28 Manifolds pressure sensor power sup...

Page 267: ...tput 18 n a 19 n a 20 Vehicle speed sensor power supply earth Power supply 21 Ignition request Digital input 22 n a 23 Side stand switch Digital input 24 Diagnostics line K Communication line 25 Clutch switch Digital input 26 Stop switch Digital input 27 CAN line L Communication line 28 CAN line H Communication line 29 Fuel pump control Power output 30 n a 31 Starter relay control Digital output 3...

Page 268: ...ensor 15 A F From ignition switch to high beam low beam 20 A NOTE There are three spare fuses G 22 MAIN FUSES H Battery charge and vehicle electric loads red and red white wires immobilizer 30 A I injection loads red and red black wires 30 A NOTE There is one spare fuse 23 INTAKE PRESSURE SENSOR Membrane sensor in which the deformation of a membrane is transformed in an electric signal It is locat...

Page 269: ...re transferred at a bit rate of about 250 kbps the nodes receive data every 20 ms i e 50 times per second CAN PROTOCOL CONTROLLER AREA NETWORK The CAN line uses the CSMA CD communications protocol Carrier Sense Multiple Access w Collision Detection Carrier Sense means that a node will determine whether the BUS link shared by all connected devices is busy before using the link to transmit a message...

Page 270: ...Warning light LED Operated by Neutral Green SMD Side stand Amber SMD EFI Oil pressure Red SMD ECU through CAN line CAN BUS LINE SIGNALS Transmitted signal Frequency Hz Engine rpm Vehicle speed Diagnostics Neutral warning light Side stand warning light Oil pressure warning light Water temperature 50 Sent signal Frequency Hz Odometer stored in injection ECU for future implementations Model identifie...

Page 271: ...T POWER UP At first power up the immobilizer control unit is blank and the LED comes on steady To store the key codes of the two keys supplied as standard Insert the first key and turn the ignition switch to ON the LED goes out for 0 5 seconds and comes back on again When the LED comes on turn the key to OFF Insert the second key within the next 20 seconds and turn the key to ON the LED goes out a...

Page 272: ... an enabled key and turn the key to ON and back to OFF 2 Insert the Master Key within 20 seconds to enable the procedure this is indicated by the immobilizer light coming on steady 3 Insert and turn to ON all keys to be enabled To confirm each key code has been stored successfully the immobilizer LED goes out for 0 5 sec 4 After storing each key code the system will wait for the next key for 20 se...

Page 273: ...ratio it is necessary for the quantity of air taken in by the engine to be equal to the theoretical amount needed to burn all the injected fuel In this case the lambda factor is 1 i e the ratio between air taken in by the engine and theoretical air necessary to burn all the injected fuel λ 1 ideal mixture λ 1 lean weak mixture λ 1 rich mixture Oxygen sensor with heater Power supply 12V Sensor tens...

Page 274: ... Water temperature 88 C 190 4 F In case the signal is lost the ECU sets the value of 88 C 190 4 F with linear increase by 0 33 C sec 32 6 F sec starting from air temperature upon start up On the instrument panel 135 C flashes and the WARNING light turns on Barometric pressure 980 hPa TPS 9 8 Uses the value from the intake pressure sensor Intake pressure Values according to engine rpm and TPS are s...

Page 275: ...ccurs TPS signal missing stepper motor signal missing low oil pressure On the Axone DEVICES STATUS page the parameter INITIALISED ECU is NO water temperature above 120 C 248 F if the ECU detects a failure of a set of signals that might compromise safe use of the vehicle For example TPS and intake pressure signals missing at the same time ...

Page 276: ...0004S003947 feature a modified wiring harness because the pick up sensor now uses a two pin connector instead of the three pin connector used in the past The new ECUs can be retrofitted to motorcycles manufactured before frame no ZD4RR00004S003947 SPARE ECU S NOTE Spare ECUs must be programmed before use look up correct mapping in the following table NEW ECU MAPPING CODE NOTE 664584 VD5G684 BIX 66...

Page 277: ...CYCLE PARTS 7 22 TUONO 1000 7 1 9 WIRING DIAGRAM ...

Page 278: ... sensor 41 Ambient pressure sensor 42 Throttle sensor 43 Double coil 44 Front cyl spark plug 45 Rear cyl spark plug 46 Front cyl injector 47 Rear cyl injector 48 Camshaft sensor 49 Pick up 50 ECU 51 Front LH turn indicator 52 LH headlight 53 RH headlight 54 LH headlight parking light 55 LH headlight low beam bulb 56 LH headlight high beam bulb 57 RH headlight high beam bulb 58 RH headlight low bea...

Page 279: ...aprilia s p a via G Galilei 1 30033 Noale VE Italy tel 39 041 5829111 fax 39 041 5829190 www serviceaprilia com www aprilia com ...

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APRILIA TUONO 1000 R, Workshop Manual

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