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•

Move the gearbox shafts together and

fit them into the support

•

Grease the sliding bushes of the forks

•

Insert the forks (5) in the specific seats

of the gearbox secondary shaft

•

Insert the gearbox secondary shaft

control rod (6) checking the presence

of the springs

Tuono V4 1100 Factory

Engine

ENG - 151

Содержание Tuono V4 1100 Factory 2021

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

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

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

Страница 4: ......

Страница 5: ...INDEX OF TOPICS PRE DELIVERY PRE DE CHARACTERISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP ...

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

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

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

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

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

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

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

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

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

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

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

Страница 17: ...osto da cifre e lettere come nell esempio sotto riportato ZD4KZA00YSXXXXXX LEGENDA ZD4 codice WMI World manufacture identifier KZ modello A00 Europa UA0 USA Tuono V4 1100 B00 Europa UB0 USA Tuono V4 1100 Factory 0 digit free Y anno di fabbricazione S stabilimento di produzione S Scorzè XXXXXX numero progressivo 6 cifre CHASSIS NUMBER The chassis number is stamped on the RH side of the headstock EN...

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

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

Страница 20: ...th progressive linkage with APS system Shock absorber with piggy back that can be electronically adjusted for hydraulic brake compression and extension and mechanically adjusted for spring pre loading Rear damper Tuono V4 1100 Sachs With progressive linkage with APS system Shock absorber with piggy back that can be adjusted for spring pre loading hydraulic brake compression and extension Rear trav...

Страница 21: ...ons use only Pirelli Diablo Super corsa SP tyres Inflation pressure 1 passenger 2 5 bar 250 KPa 36 26 PSI 2 passengers 2 8 bar 280 KPa 40 61 PSI Supply POWER SUPPLY Specification Desc Quantity Fuel Unleaded gasoline E10 95 R O N FUEL SUPPLY SYSTEM Specification Desc Quantity Throttle body diameter 48 mm 1 89 in Type Electronic injection with 2 injectors per cylinder 4 motorised throttle bodies Rid...

Страница 22: ...PRESSION WITHOUT INSERTED COL LAR OR BUSH M4 M5 M6 Tightening torque 1 5 Nm 1 10 lb ft 2 Nm 1 47 lb ft 3 Nm 2 21 lbf ft CAUTION THE SCREWS WITH THREAD LOCK SEALANT PRE IMPREGNATED MUST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED BEFORE FITTING THE NEW SCREWS CLEAN THE THREADED HOLES CAREFULLY MAKING SURE THAT ALL TRACES OF THE OLD THREAD LOCK SEALANT HAVE BEEN ELIMINATED Chassis Char...

Страница 23: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Страница 24: ...e Description 020845Y Engine support 020846Y Containment tray plastic plugs 020847Y Flywheel extractor 020914Y Flywheel stop 020849Y Clutch retainer tool 020850Y Primary gear lock Special tools Tuono V4 1100 Factory S TOOLS 24 ...

Страница 25: ...iming pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020981Y Lever for disarming the hydraulic tension er of the timing chain 020980Y Piston assembly ring 020857Y Crankshaft support U bolt Tuono V4 1100 Factory Special tools S TOOLS 25 ...

Страница 26: ...P8140199 Tool storage panel 8140426 Hooks for panel 020860Y Motor support extension 020862Y Punch assembly cage with rollers gear box control rod 020863Y Punch assembly cage with rollers des modromic drum 020864Y Engine support plate Special tools Tuono V4 1100 Factory S TOOLS 26 ...

Страница 27: ...ort for camshaft gear on head 020883Y Fitting removing timing chain tensioner tool 020709Y Engine support AP8140187 U bolt for motor support 020376Y Adaptor handle 020363Y 20mm oil seal guide Tuono V4 1100 Factory Special tools S TOOLS 27 ...

Страница 28: ...Y 25 mm guide 020359S 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Bearing extractor AP8140179 Valve springs compressor 0277308 Guide bushing for gearbox secondary shaft Special tools Tuono V4 1100 Factory S TOOLS 28 ...

Страница 29: ...for fitting clutch bushing AP8140146 Weight AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140149 Guard for assembly operations AP8140190 Steering tightening tool 01761 04 Ohlins fork cap ring nut Tuono V4 1100 Factory Special tools S TOOLS 29 ...

Страница 30: ...clamp 020889Y Wrench for locking pumping unit ring nut 020890Y Support rod of pumping unit stanchion AP8140181 Tool for checking fuel pressure 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles Special tools Tuono V4 1100 Factory S TOOLS 30 ...

Страница 31: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Страница 32: ...I I I Spark plug R R Drive chain 3 I L I L I L I L I L Clutch cable L L L L L Exhaust valve control cables 5 A A A A A Crown wheel sprocket 5 I I I I Steering bearings and steering play 5 I I I I I Wheel bearings Wheels 5 I I I I I Diagnosis by tool I I I I I Brake discs 5 Pads wear 2 I I I I I Air filter 5 I R I R Engine oil filter 5 R R R R R Raked I I General vehicle operation 5 I I I I I Valve...

Страница 33: ... 621 mi 4 Replace every 4 years 5 Every 5 000 Km 3 106 mi if the vehicle is used for racing 6 Every 10 000 Km 6 213 mi if the vehicle is used for racing 7 Replace at whichever of the following occurs first 40 000 km 24 854 miles or 4 years SCHEDULED MAINTENANCE TABLE km x 1 000 or months maximum 1 1 10 10 20 20 30 30 40 40 Rear shock absorber bearings linkage systems 5 I I Motorcycle set up 5 I I ...

Страница 34: ...F THE VEHICLE STARTING FROM THE SERVICE OF 10 000 Km OR 10 MONTHS Recommended products Piaggio Group recommends the use of prod ucts from its Castrol official partner for the scheduled maintenance of its vehicles Only use lubricants and fluids which meet or ex ceed the performance characteristics specified This also applies when topping up only TABLE OF RECOMMENDED PRODUCTS Product Description Spe...

Страница 35: ... disconnect them After removing the screws holding the coils disconnect them from the spark plugs and remove them Using a special spark plug wrench un screw and remove them REAR SPARK PLUGS Cylinder 1 To proceed with the removal of the cylinder 1 spark plug proceed as described After removing the fixing screw of main wiring harness support release it from the filter housing by lifting it as indica...

Страница 36: ...t While refitting make sure you pass the coil wiring harness behind the wiring harnesses on the filter housing Using a special spark plug wrench un screw and remove it Cylinder 3 To proceed with the removal of the cylinder 3 spark plug proceed as described Release the connector from the sup port on the filter housing and discon nect it Maintenance Tuono V4 1100 Factory MAIN 36 ...

Страница 37: ... efficiency and check the electrode gap If they are not within the parameters replace them Engine oil Check THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km 10 miles IN EXTR...

Страница 38: ...he level is correct if it reaches the MAX level approximately Otherwise top off the engine oil CAUTION THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MARKING OR EXCEED THE MAXIMUM MARKING AN OIL LEVEL NOT WITHIN THE MINIMUM AND MAXIMUM MARKINGS MAY CAUSE SEVERE ENGINE DAMAGE Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY Place a container with suitable capac...

Страница 39: ... 1 3 of its capacity with engine oil before fit ting Screw and tighten the drainage plug Introduce 4 l 0 88 UK gal 1 06 US gal engine oil of the specified type Screw on the filler cap Warm up the engine up by running it for a few minutes then switch it off After thirty seconds check the level with a oil level dipstick Top up if necessary CAUTION THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MAR...

Страница 40: ...the engine oil fil ter from its seat NOTE NEVER REUSE AN OLD FILTER Spread a thin layer of oil on the sealing ring of the new engine oil filter Insert and screw the new engine oil filter in the seat filling the filter to 1 3 of its capacity with engine oil before fitting See also Replacement Air filter To remove the air filter the fuel tank must be re moved to be able to reach the filter housing a...

Страница 41: ...harness from the two cable glands on the filter housing From the support on the filter housing disconnect the cylinder 3 coil connec tor Remove the three screws fixing the ECU support to the filter housing Remove the control unit complete with support Tuono V4 1100 Factory Maintenance MAIN 41 ...

Страница 42: ...ess support release it from the filter housing by lift ing it as indicated Remove the quick shift connector from its seat Remove the nine fixing screws of the filter housing cover Remove the air filter retainer by lifting it Maintenance Tuono V4 1100 Factory MAIN 42 ...

Страница 43: ...oceed as follows COVER REMOVAL Disconnect the ENGINE connector from the control unit After having disconnected the VEHI CLE connector from the control unit release the wiring harness from the two cable glands on the filter housing Remove the three screws fixing the ECU support to the filter housing Tuono V4 1100 Factory Maintenance MAIN 43 ...

Страница 44: ...ed the fixing screw of the engine wiring harness support release it from the filter housing by lift ing it as indicated Remove the quick shift connector from its seat Remove the nine fixing screws of the filter housing cover Maintenance Tuono V4 1100 Factory MAIN 44 ...

Страница 45: ...t from the supports on the filter housing the coil connectors and the power supply connector from the main wiring harness to the engine wir ing harness Remove the filter housing cover BASE REMOVAL After having removed the filter housing cover proceed with removing the air filter retainer by lifting it Tuono V4 1100 Factory Maintenance MAIN 45 ...

Страница 46: ...side of the vehi cle remove the screw that fastens the front bank oil pressure sensor to the base of the filter housing removing al so the gear sensor connector support bracket Operating on the right side of the vehi cle remove the screw that fastens the rear bank oil pressure sensor to the base of the filter housing Maintenance Tuono V4 1100 Factory MAIN 46 ...

Страница 47: ...y pipe of the blow by valve on the left and the vapour recovery pipe of the sas valve on the right Operating on the left side of the vehi cle remove the clamp that fastens the engine wiring harness to the filter hous ing base Release from the supports the connec tors of the front bank coils located on the filter housing base Tuono V4 1100 Factory Maintenance MAIN 47 ...

Страница 48: ...particular at tention to the following operations CLAMP PRE FITTING Place a suitably sized clamp on the en gine wiring harness next to the grey taping and secure it to the filter housing base Do not tighten the clamp to facilitate the connection of the front bank coil con nectors and of the lower injector wiring harnesses Subsequently after having placed the filter housing base close the clamp com...

Страница 49: ...zzante lato frizione Rimuovere il coperchio frizione Agendo sul dado di fissaggio dell ing ranaggio primaria ruotare l albero mo tore nel senso di rotazione del motore senso di marcia fino a quando le val vole non sono in tensione Use a feeler gauge to check the clear ance between the cam of the shaft and the relative tappet for both front head shafts Characteristic Acceptable values with control ...

Страница 50: ...i gli alberi della testa posteriore Characteristic Acceptable values with control clearance be tween cam and valve intake 0 10 0 15 mm 0 0039 0 0059 in ex haust 0 20 0 25 mm 0 0079 0 0098 in Front cylinder head valves Verificare il gioco valvole testa anteriore se è nec essario ripristinare i valori corretti del gioco pro cedere come descritto di seguito Rimuovere entrambi i coperchi testa i coper...

Страница 51: ...l motore senso di marcia Avvitare l apposita spina dal lato vola no nel bulino presente sull albero mo tore Specific tooling 020852Y Crankshaft timing pin Inserire la spina di allineamento dell al bero a camme d aspirazione con il foro sul cavallotto Specific tooling 020851Y Camshaft timing pin Allentare la seconda vite dell ingranag gio di comando albero a camme Tuono V4 1100 Factory Maintenance ...

Страница 52: ...zo per il sup porto dell ingranaggio albero a camme Fissarlo alla testa tramite le due viti Specific tooling 020956Y Support for camshaft gear on head Rimuovere la seconda vite dell ingra naggio di comando albero a camme Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool s spacer Maintenance Tuono V4 1100 Factory MAIN 52 ...

Страница 53: ... gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Utilizzando una calamita rimuovere i bicchierini Utilizzando una calamita rimuovere le pastiglie calibrate e sostituirle con quelle adeguate per ripristinare il cor retto valore del gioco valvole Consultare il paragrafo Spessore pastiglie calibrate per individuare uno spessore ade guato C...

Страница 54: ...i centraggio in serire le sette viti indicate avvitandole a mano Utilizzare delle nuove rondelle in rame sulle quattro viti vicine ai fori candela Allentare la vite del fermo dell ingra naggio di distribuzione sull attrezzo Spostare l ingranaggio stesso dall at trezzo di supporto all albero a camme CAUTION OPERARE CON CAUTELA PER EVITARE CHE L INGRA NAGGIO DI DISTRIBUZIONE SI SCOLLEGHI DALL AL BER...

Страница 55: ...ero motore senso di mar cia quanto basta fino a rendere visibile il secondo punto di fissaggio dell ing ranaggio Posizionare Loctite 243 frenafiletti sul la parte filettata della seconda vite dell ingranaggio distribuzione che va sostituita ad ogni rimontaggio e serrar la a coppia Ruotare l albero motore senso di mar cia fino a ritornare nella posizione precedente in cui erano allineati i fori di ...

Страница 56: ...zanti il coperchio la to alternatore e rimuovere il coperchio frizione Portare il pistone del cilindro 1 pistone posteriore sinistro al PMS Iniziare a ruotare l albero motore di 450 un giro completo 90 agendo sul dado di fissaggio dell ingranaggio primaria senso di rotazione del mo tore e appena è accessibile la prima vite di fissaggio dell ingranaggio di dis tribuzione rimuoverla Completare la ro...

Страница 57: ... di comando albero a camme Rimuovere la spina dall ingranaggio di comando albero a camme Svitare e rimuovere le tre viti 1 il cav allotto 2 e il tubetto dell olio 3 Rimuovere la seconda vite dell ingra naggio di comando albero a camme CAUTION OPERARE CON CAUTELA PER EVITARE CHE L INGRA NAGGIO DI DISTRIBUZIONE SI SCOLLEGHI DALL AL BERO A CAMME Tuono V4 1100 Factory Maintenance MAIN 57 ...

Страница 58: ...ool s spacer Svitare e rimuovere le sette viti proce dendo per stadi e in diagonale Recuperare le rondelle in rame dalle viti vicino ai fori candela Rimuovere i cavallotti completi di anelli o ring e spine di centraggio Remove the intake and exhaust cam shafts If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake cams...

Страница 59: ...ore ade guato CAUTION REMOVE THE TAPPET CAREFULLY AS THE PAD MAY FALL INTO THE ENGINE Riposizionare i bicchierini Riposizionare gli alberi a camme pre stando attenzione affinché siano cor rettamente fasati Se i due alberi a camme sono correttamente fasati il dente dell ingranaggio dell albero a camme di scarico indicato con un bulino è inserito nella go la dell ingranaggio dell albero a camme di a...

Страница 60: ...albero a camme CAUTION OPERARE CON CAUTELA PER EVITARE CHE L INGRA NAGGIO DI DISTRIBUZIONE SI SCOLLEGHI DALL AL BERO A CAMME Rimuovere l attrezzo supporto ingra naggio di comando albero a camme sulla testa Posizionare Loctite 243 frenafiletti sul la prima vite dell ingranaggio di distrib uzione e avvitarla a mano senza ser rarla a coppia Posizionare il cavallotto il tubetto dell olio e le tre viti...

Страница 61: ...ibuzione che va sostituita ad ogni rimontaggio e serrar la a coppia Ruotare l albero motore senso di mar cia fino a ritornare nella posizione precedente in cui erano allineati i fori di albero a camme e cavallotto inserire la spina di riferimento e contemporanea mente verificare tramite la spina di ri ferimento albero motore che esista un perfetto allineamento tra il foro dal lato volano e il buli...

Страница 62: ... mm 0 0716 in 1 85 mm 0 0728 in 1 87 mm 0 0736 in 1 90 mm 0 0748 in 1 92 mm 0 0756 in 1 95 mm 0 0768 in 1 97 mm 0 0775 in 2 mm 0 0787 in 2 02 mm 0 0795 in 2 05 mm 0 0807 in 2 07 mm 0 0815 in 2 1 mm 0 0827 in 2 12 mm 0 0835 in 2 15 mm 0 0846 in 2 17 mm 0 0854 in 2 2 mm 0 0866 in 2 22 mm 0 0874 in Maintenance Tuono V4 1100 Factory MAIN 62 ...

Страница 63: ...n 2 6 mm 0 1024 in 2 62 mm 0 1031 in 2 65 mm 0 1043 in 2 67 mm 0 1051 in 2 7 mm 0 1063 in 2 72 mm 0 1071 in 2 75 mm 0 1083 in 2 77 mm 0 1090 in 2 8 mm 0 1102 in 2 82 mm 0 1110 in 2 85 mm 0 1122 in 2 87 mm 0 1129 in 2 9 mm 0 1142 in 2 92 mm 0 1150 in 2 95 mm 0 1161 in 2 97 mm 0 1169 in 3 mm 0 1181 in 3 02 mm 0 1189 in 3 05 mm 0 1201 in 3 07 mm 0 1209 in 3 10 mm 0 1220 in 3 12 mm 0 1228 in 3 15 mm 0...

Страница 64: ...maximum and LOW minimum marks WARNING CARRY OUT THE CHECK AND TOP UP THE REFRIGER ANT LIQUID WITH THE ENGINE SWITCHED OFF AN COLD Top up Per effettuare il rabbocco dell impianto di raffred damento è necessario rimuovere la carena later ale destra Successivamente operare come de scritto Rimuovere il tappo di riempimento del vaso di espansione Rabboccare l impianto verificando il livello mediante gl...

Страница 65: ... RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESER VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE TO AVOID SPILLING FLUID WHILE TOPPING UP KEEP THE LEVEL OF THE FLUID IN THE RES ERVOIR PARALLEL WITH THE EDGE OF THE RESERVOIR ...

Страница 66: ...HE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE LEVER IS TOO LONG OR IN CASE OF FLUID LOSS IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM HAVE THIS PROCEDURE PERFORMED BY AN Authorised Aprilia Dealer Rear braking system Unscrew and remove the upper nut 5 from the rear brake pump Top up the reservoir with the recom mended brake fluid to reach the correct level on the sight glass 6 CAUTION ONLY...

Страница 67: ...nd Partially undo the screw 4 Turn the cam 5 searching for the best position for the pedal Tighten the screw 4 and check the cam is stable in position Clutch system Adjusting the lever Adjust the clutch when the engine stops or the ve hicle tends to move forward even when clutch lever is operated and the gear engaged or if the clutch slides resulting in acceleration delay con sidering the engine r...

Страница 68: ... Make sure that the engine does not stop or that the vehicle does not tend to move or that the clutch does not slip during acceleration or while rid ing Headlight adjustment NOTE IN COMPLIANCE WITH LOCAL LEGISLATION SPECIFIC PROCEDURES MUST BE FOLLOWED WHEN ALIGNING THE LIGHTS To quickly check if the headlamp is aimed correct ly place the vehicle on a level surface 10 m 32 8 ft from a vertical wal...

Страница 69: ...be used to adjust the vertical alignment of the low beam headlight beam NOTE CHECK THAT THE VERTICAL ALIGNMENT OF THE BEAM IS CORRECT HIGH BEAM HEADLIGHT Operating from underneath the head lamp unit turn the adjuster screw 3 TIGHTEN clockwise to lower the light beam LOOSEN anticlockwise to raise the beam This adjuster screw may be used to adjust the vertical alignment of the high beam headlight be...

Страница 70: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Страница 71: ...Components arrangement Key 1 Side stand sensor 2 Fuel pump 3 Instrument cluster Tuono V4 1100 Factory Electrical system ELE SYS 71 ...

Страница 72: ... sensor 17 Rear speed sensor 18 Headlamp 19 Rear turn indicators 20 Licence plate light 21 Taillight 22 Horn 23 Voltage regulator 24 Battery 25 Secondary fuses 26 Main fuse 27 11SM control unit 28 Rear brake switch 29 Stator with timing sensor 30 Coils 31 Starter motor 32 Oil pressure sensor 33 Inertia platform 34 Accelerator control 35 Quick Shift 36 a PRC commands 37 Modulator ABS control unit 3...

Страница 73: ...efine the correct cable harness routing layout to ensure the reliability of the vehicle Materials used and corresponding quantities The electrical system consists of the following wiring harnesses and parts 1 x Main vehicle wiring harness 1 x Licence plate holder wiring harness 1 x Engine Battery Earth Cable Only for RSV 1100 Factory OHLINS ASC 1 x Main vehicle wiring harness 1 x Ohlins fork wirin...

Страница 74: ... Check the ground fastening on the starter motor starter motor positive and relative hood Check the taillight connection Check the connection between the number plate holder wiring harness and the main wiring harness Check the fuel pump connection Check the regulator connection Check fastening of the chassis engine ground cable Check the flywheel regulator connection Check the Lambda connection fr...

Страница 75: ...ARE CIRCLED IN GREEN IN THE VARIOUS PHO TOS THESE CONNECTORS HAVE BEEN LISTED AS THEY ARE MORE CRITICAL THAN OTH ERS AND THEIR DISCONNECTION MAY CAUSE VEHICLE BREAKDOWN OR MALFUNCTION NATURALLY IT IS ALSO NECESSARY THAT ALL OTHER CONNECTORS CONNECTED COR RECTLY TO ENSURE THAT THE VEHICLE FUNCTIONS CORRECTLY THE INSTRUCTIONS FOR ROUTING AND FASTENING THE WIRING HARNESS THROUGHOUT THE VEHICLE MUST B...

Страница 76: ...General wiring diagram Legenda 1 Connettori multipli 2 Claxon 3 Devioluci sinistro 4 Devioluci sinistro 2 manettino Electrical system Tuono V4 1100 Factory ELE SYS 76 ...

Страница 77: ...steriore 21 Relè comando ventola 22 Ventola 23 Sensor box 24 Fusibili secondari 1 FUSE 1 25 Fusibili sospensioni Ohlins FUSE 2 Ove previsto 26 Fusibili secondari 3 FUSE 3 27 Fusibili ABS FUSE 4 28 Generatore 29 Regolatore di tensione 30 Motorino di avviamento 31 Relè di avviamento Fusibile principale 30A 32 Batteria 33 Interruttore cavalletto laterale 34 relè iniezione principale 35 Relè pompa ben...

Страница 78: ...e map 2 63 Farfalla motorizzata 2 64 Sensore map 1 65 Farfalla motorizzata 1 66 Sensore temperatura aria 67 Sensore temperatura acqua 68 Pick UP sensore giri 69 Sensore pressione olio 70 Centralina 11 MP 71 Connettore cablaggio motore veicolo 72 Presa diagnostica OBD2 73 Centralina AMP ove previsto 74 Fanale anteriore completo LED 75 DRL Indicatore di direzione anteriore sinistro LED 76 LED anabba...

Страница 79: ...ING PROCEDURES ON THE VEHICLE CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V CONNECTOR CHECK PROCEDURE The procedure includes the following checks 1 Observation and check of the connector correct position on the component or on the coupling con nector making sure that the locking catch is re leased 2 Observation of the terminals on the connector no rust marks or dirt should be present and it is impor...

Страница 80: ...d to the ground of the vehicle Tester set the tester selector to the continuity symbol and place one of the tester probes on the vehicle ground point or on the battery negative pole and the other probe on the cable under inspection Normally the tester will sound an audible signal to confirm continuity in the section of circuit tested Continuity may also be tested by setting the tester selector to ...

Страница 81: ...sible Press OK and start programming the keys NOTE IF THE IMMOBILIZER ANTENNA IS DISCONNECTED YOU WILL NOT BE ABLE TO START KEY PROGRAMMING Enter the USER CODE to continue If the code entered is correct the first key is stored At this point on the digital display of the motorcycle after the automatic restart of the dynamic presentation screen a message will appear with a countdown of 20 seconds to...

Страница 82: ... page injector icon Diagnosis In case of malfunction of certain or gans the digital display of the instru ment panel may display errors To check and diagnose the specific com ponent check the dedicated section Fuses It is necessary to check the fuses whenever an electrical component fails to operate or malfunctions or when the engine does not start Check the secondary fuses first and then the prim...

Страница 83: ...fuse at a time and check whether the filament 2 is broken Before replacing the fuse find and solve if possible the reason that caused the problem If the fuse is damaged replace it with one of the same current rating NOTE IF THE SPARE FUSE IS USED REPLACE WITH ONE OF THE SAME TYPE IN THE CORRESPONDING FITTING Tuono V4 1100 Factory Electrical system ELE SYS 83 ...

Страница 84: ...er for OBD positive key on power for USB positive key on power for the timer fitting F 5A fuse Positive key on power for headlamp load G 7 5A fuse Positive key on power for smart EC H spare fuses 5 A 2 7 5 A I 10A fuse ABS solenoid valves L 25A fuse ABS motor pump M fuse of 15A Fan power feed N fuse of 20A Fan relay power supply ECU power supply fuel pump relay power supply rear and front lambda p...

Страница 85: ... Specification Desc Quantity O 30A fuse Battery charging all vehicle utilities P spare fuse 30 A The main fuse is located on the rear part of the motorcycle under the tail fairing passenger saddle CAUTION REMOVING THE 30A FUSE WILL RESET THE DIGITAL CLOCK TRIP INFORMATION AND CHRONOMETER TIMES Control unit ASC CONTROL UNIT ELECTRONIC SUSPENSION CONTROL UNIT IF AVAILABLE RIMOZIONE Dopo aver rimosso...

Страница 86: ... indicates the hardware version BOOT version Software version Map identification DIAGNOSTIC TOOL ACTIVATIONS Suspension test Softest setting min damping Minimum damping preload check Suspension test Hardest setting max damping Maximum damping preload check DIAGNOSTIC TOOL ERRORS ASC ELECTRONIC SUSPENSION ECU ERROR Code Description Symptoms 504900 Internal electronic fault 504600 Calibration Checks...

Страница 87: ... angular value sensor signal D08605 Invalid WZ angular value sensor signal D08606 Invalid front wheel speed sensor signal D08607 Invalid rear wheel speed sensor signal D08608 Invalid front brake pressure sensor signal D08609 Invalid rear brake pressure sensor signal D0860A Invalid accelerator sensor signal D0860B Invalid bank angle sensor signal D0860C Invalid suspension mode sensor signal D0860D ...

Страница 88: ...ttrico Ogni livello il cui componente principale coinvolga la centralina Posizione sul veicolo sopra cassa filtro connettore su centralina connettore da 80 PIN ENGINE di cui 77 attivi connettore da 66 PIN VEHICLE di cui 53 attivi Pin out Vedi paragrafo CONNETTORI screen page example values with key ON Drawing number identified inserted by the manufacturer HW number indicates the Hardware number Ha...

Страница 89: ...4 Front cylinders estimated intake pressure 2 and 4 Actuated advance real cylinder advance Battery voltage Rear lambda 1 voltage indicates the rear bank lambda probe 1 voltage Front lambda 2 voltage indicates the front bank lambda probe 2 voltage Rear lambda 1 correction rear bank lambda 1 correction Front lambda 2 correction front bank lambda 2 correction Rear bank lambda 1 lambda generated from ...

Страница 90: ...ntrol front bank lambda 2 control Rear thr val auto self learn rear throttle valve automatic self learning Front thr val auto self learn front throttle valve automatic self learning Engine status Engine mode Han Gearbox in neutral Gear engaged indicates the hear engaged Fan relay Permission from the immobilizer Tone wheel synch tone wheel synchronization status Side stand Fall sensor RUN STOP swit...

Страница 91: ... heater Rear cul 1 low inject rear bank cylinder 1 lower injector Front cul 2 low inject front bank cylinder 2 lower injector Rear cul 3 low inject rear bank cylinder 3 lower injector Front cul 4 low inject front bank cylinder 4 lower injector Rear cul 1 upp inject rear bank cylinder 1 upper injector Front cul 2 upp inject front bank cylinder 2 upper injector Rear cul 3 upp inject rear bank cylind...

Страница 92: ...HUT DOWN P060B A D converter Electrical diagnosis Circuit not functioning Error cause Replace the injection control unit The instrument panel indicates this error by lighting up in a fixed manner the MI warning light and by flashing the general warning light NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT DOWN P1301 top lights relay error Electrical diagnosis short circuit to positiv...

Страница 93: ...the fact that the level 2 safety system comparison between requested torque and calculated torque detected a fault the control unit reset the engine severity C The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Perform the troubleshooting for the other detected errors P060C Safety Engine Stop Error cause Due to the fact that the safety system d...

Страница 94: ...rument panel indicates this error by lighting up in a fixed manner the MI warning light Troubleshooting Contact technical service NOTE THIS ERROR DISABLES THE TRACTION CONTROL P1650 Engine events configuration Checksum calculation error Error cause Corrupt Flash eeprom hardware problem Upload e g in service of an incompatible software version therefore missing the reference check sum This error is...

Страница 95: ...sistema e la funzione di autodiagnosi Livello appartenenza schema elettrico Centralina ASC Posizione sul veicolo sulla parte anteriore all interno del supporto cruscotto connettore su centralina connettore da 34 PIN di cui 24 attivi Pin out Vedi paragrafo CONNETTORI Battery Funzione Fornire alimentazione elettrica al veicolo la batte ria al litio BS BATTERY LITIO BSLi 04 è già atti vata carica e s...

Страница 96: ... Error cause If too high too high a voltage has been detected at PIN 42 If too low too low a voltage has been detected at PIN 42 The instrument cluster indicates the presence of this error with the MI warning light on fixed Troubleshooting If too high check that the voltage regulator is working correctly If too low check voltage regulator connectors engine vehicle wiring harness connector and ECU ...

Страница 97: ...TRACTION CON TROL AND THE CRUISE CONTROL Butterfly valve in exhaust Function Used to reduce the noise at the exhaust The ex haust valve is controlled as follows With engine off completely closed 0 With engine on depending on the gear engaged the exhaust valve has differ ent opening values according to the engine speed and load Above 6 000 rpm the valve is always open except for neutral With the mo...

Страница 98: ...ve closed 100 valve open CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES Exhaust valve Not determined searching activation at key ON in operation stopped due to detected faults zero searching NOTES If there is no pro...

Страница 99: ...ide the established range Check the correct voltage of the two cables of the valve If excessive duration check if the valve cables are energised if they are not energised energise them if ok check if the mechanical rotation of the exhaust valve occur without friction or delays if not ok restore the normal valve rotation if ok check the electrical char acteristics of the motor if not ok replace the...

Страница 100: ...the instrument panel if there is no ground with key ON check if there is ground continuity at the connector PIN 2 if there is ground disconnect the instrument panel connector as well and if there is still ground restore the Black Red cable and if there is not replace the instrument panel if there is no ground check if PIN 3 or PIN 2 on the motor have ground continuity if they do replace the motor ...

Страница 101: ...ter does not correspond to the one set by the control unit This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light Troubleshooting Perform a mechanical check of the valve check its normal rotation with the cables discon nected from the motor manually operate the cables and notice the movement regularity checking the complete stroke of...

Страница 102: ...l the valve could stay stuck in the closed position In the event of a CAN line malfunction the valve returns to the open position In the event of a check removal or replacement of one or more system cables valve motor a cali bration procedure is required CAUTION BEFORE CARRYING OUT THIS OPERATION CHECK THAT THE BATTERY VOLTAGE IS HIGHER THAN 12 5 V CAUTION WORK ON THE MOTOR OF THE EXHAUST THROTTLE...

Страница 103: ...attery voltage is NOT below 12V Check that the cylinders are in their seat and are NOT obstructed If the cylinders are obstructed put them in their seats straight Check that the valve spring on the si lencer is in its seat Tuono V4 1100 Factory Electrical system ELE SYS 103 ...

Страница 104: ...JUSTMENT SCREWS UP AGAINST THE SUPPORT PLATE WELDED TO THE SI LENCER Connect the PADS and carry out the valve zero actuator in the corresponding valve fully open position CAUTION CHECK THAT THE PULLEY HAS THE END STOP RESTING AGAINST THE END STOP OF THE SILENCER Electrical system Tuono V4 1100 Factory ELE SYS 104 ...

Страница 105: ... opening cable adjuster screw up to the value corresponding to the value Y see values in the table CAUTION TURN THE ADJUSTER SCREW FULLY ANTI CLOCKWISE DIRECTION FOR TENSIONING THE ADJUSTER SCREW KEEPING THE COUNTER NUT STILL DO NOT TURN CLOCKWISE FOR ANY CORRECTIONS SINCE THE AD JUSTMENT IS DISTORTED DUE TO THE PLAY IF IT GOES BEYOND THE REQUIRED VALUE FULLY TIGHTEN THE ADJUSTER SCREW AND REPEAT ...

Страница 106: ...GE AT THE POINT SHOWN IN THE IMAGE BELOW Presa USB Il connettore per il collegamento della presa USB è situato all interno del supporto cruscotto ed è ac cessibile dal lato sinistro del veicolo Per accedere al connettore è necessario rimuo vere la carrozzeria anteriore Aprilia V4 MP Tecnology Sincronizzazione To use the system V4 MP the synchronisation that differs depending on the operating syste...

Страница 107: ...ooth is enabled the smart phone automatically searches devi ces When the PMP ECU has been recognized it appears in the MY DE VICES list as PMP Click on PMP and wait for the smartphone to con nect When connected the PMP shows Connected Now the PMP is connected to the phone and in the V4 MP App you should note the motorcy cle data transmission After the first connection the system connects automatic...

Страница 108: ...ueTooth active green button Wait for the smartphone to rec ognize the PMP ECU until you see PMP in Available devices list When the PMP is found click on the PMP line and make sure the smart phone is connected Once connected the PMP is added to the Paired devi ces list and in the menu PMP appears the message Paired Now the PMP is connected to the phone and in the V4 MP App you should note the motor...

Страница 109: ...SITION BEFORE THE APP IS LAUNCHED CAUTION AFTER THE KEY IS OFF IT WILL BE NECESSARY TO WAIT FOR ABOUT 20 SECONDS TO EN SURE THAT THE WIRELESS CONNECTION IS CLOSED IN CASE OF CONNECTION FAILURE JUST EXIT THE APPLICATION USING THE APPROPRIATE BUTTON CLOSE IT FROM THE BACKGROUND MENU AND MANUALLY RESTART IT IF THE PREVIOUS DEVICE IS NOT IN THE AREA AFTER 20 SECONDS THE SYSTEM WILL BE AVAILABLE TO CON...

Страница 110: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Страница 111: ...ight of the vehicle to the semi handlebars and to a hoist Place the rear stand Removing the engine from the vehicle To proceed with the removal of the engine from the vehicle proceed as described Unscrew and remove the filler plug of the coolant radiator Use a container with a suitable capaci ty and operating from the left side of the vehicle remove the discharge screw of the cooling system Use a ...

Страница 112: ...de electric fan and remove the safety clamp applied on the connector Remove the clamp that fastens the generator s alternator s wiring har nesses the oil pressure bulb the front bank lambda probe and the left side electric fan Temporarily move away the canister by blocking it using circlips to facilitate the subsequent operations Engine from vehicle Tuono V4 1100 Factory ENG VE 112 ...

Страница 113: ...it Release the connector of the demand sensor from the exhaust valve motor support and disconnect it Extract the water breather pipe of the expansion tank from the cable gland connected to the support bracket of the radiators and remove the cable gland that fastens the breather pipe to the demand sensor s wiring harness Tuono V4 1100 Factory Engine from vehicle ENG VE 113 ...

Страница 114: ...e of the expansion tank Remove the metal clamp and discon nect the oil pipe from the sump Remove the two fixing screws of the radiators support bracket Disconnect the front bank lambda probe connector and release it from its support Engine from vehicle Tuono V4 1100 Factory ENG VE 114 ...

Страница 115: ...he thermostatic valve Remove the metal clamp and discon nect the oil pipe from the coupling Move the metal clamp and disconnect the cooling system s pipe from the ra diator Remove the indicated clamp and re lease the wiring harnesses from the radiator s support Tuono V4 1100 Factory Engine from vehicle ENG VE 115 ...

Страница 116: ...rom the support on the left side and remove both radiators by extracting them at the same time from the right side Loosen the metal clamp that fastens the front manifolds to the central ex haust manifold Unscrew the four fixing screws of the front bank and remove them Engine from vehicle Tuono V4 1100 Factory ENG VE 116 ...

Страница 117: ...eads fixing screw and release the wiring harnesses Move the wiring harness to the outside and fasten them using a circlip Remove the internal cable gland on the left side of the vehicle to facilitate the engine removal Tuono V4 1100 Factory Engine from vehicle ENG VE 117 ...

Страница 118: ... and removed the fixing nut of the start er motor power cable release the wir ing harness Loosen the clutch cable tensioning by using the adjuster nuts and disconnect it from the transmission lever and from the cover Remove the fastener screw of the gearbox lever and extract it from the primary shaft Engine from vehicle Tuono V4 1100 Factory ENG VE 118 ...

Страница 119: ...he rear bank lambda probe connector and release it from its support Release the springs and remove the central exhaust manifold by extracting it from the bottom Remove the rubber cable ties and ex tract the tank s breather pipe Tuono V4 1100 Factory Engine from vehicle ENG VE 119 ...

Страница 120: ...s and after hav ing removed the quick shift connector extract its wiring harness and the wir ing harness of the side stand s switch Unscrew the two fixing screws and re move the rider s footboard support from the left side Loosen the final drive chain tension to facilitate the sprocket removal Remove the fixing screw and retrieve the spring washer the T bushing and extract the sprocket from the se...

Страница 121: ...ove the support Unscrew the fixing nuts of the rear manifolds and extract then from the rear Unscrew the two side stand fixing screws and remove it Remove the screw that fastens the ABS modulator support to the chassis and the screw that fastens the metal plate to the support Tuono V4 1100 Factory Engine from vehicle ENG VE 121 ...

Страница 122: ... ABS modulator with the sup port extract the metal plate at the rear Disconnect the wiring harnesses from the cable gland inside the chassis on the right front side and after having moved them to the outside fasten them using a circlip together with the exhaust valve motor to facilitate the engine removal Engine from vehicle Tuono V4 1100 Factory ENG VE 122 ...

Страница 123: ...o the chassis and re trieve the internal plate Completely unscrew the adjuster screw Unscrew the nut of the lower pin and extract it from the left side of the vehi cle Operating from the right side of the ve hicle completely unscrew the adjuster screw Operating from both sides remove the four screws that fasten the engine to the chassis and make sure to retrieve the spacer on the right side of the...

Страница 124: ...alling the engine to the vehicle To install the engine on the vehicle perform the operations below Before aligning the engine retainers place on the frame the internal and external right and left inserts with the precautions described below Adjustment of engine height relative to the chassis is determined by properly inserts placed on the chassis front position and on the engine matching the fixin...

Страница 125: ...WER LEFT REAR INSERT 5mm 0 19 in ARE EQUAL Check that the adjuster bushings on the right side of the chassis are com pletely unscrewed Lift the engine and align it with the fix ing holes on the chassis Tuono V4 1100 Factory Engine from vehicle ENG VE 125 ...

Страница 126: ...ly for the right side and the lower pin inserting it from the left side together with the washer to align the engine Tighten to the specified torque only the two front screws on the left side Extract the pin until it allows screwing at the specified torque the two adjuster screws on the right side of the chassis Refit the pin and after having inserted the upper rear screw together with the washers...

Страница 127: ...stem Fit the central manifold by connecting the rear manifolds making sure to pass the rear bank lambda probe wir ing harness inside the metal cable gland Connect the springs that hold the rear manifolds joined with the central mani fold Place the engine spacer on the left side of the vehicle and secure it by tighten ing the four screws to the specified torque Tuono V4 1100 Factory Engine from veh...

Страница 128: ...er on the fix ing screw tighten the screw to the specified torque Place the left rider footrest support on the chassis insert the two fixing screws and tighten them to the speci fied torque Refit the wiring harness of the quick shift and of the side stand switch con necting the connectors with their coun terparts Secure the wiring harnesses with the cable tie Engine from vehicle Tuono V4 1100 Fact...

Страница 129: ...e correct chain play Connect the rear bank lambda probe connector engaging in it the specific support and this in turn to the chain guide Restore the fuel tank breather pipe and fasten it using the rubber cable tie to gether with the quick shift wiring har ness the side stand switch wiring harness and the rear bank lambda probe wiring harness Fit the sprocket cover and secure it us ing the three s...

Страница 130: ...le and using the adjuster nuts adjust the tension and check the play on the handlebar lever Restore the front right internal cable gland on the chassis Insert the main wiring harness branch in the right side cable gland and place the discharge valve support in its seat Engine from vehicle Tuono V4 1100 Factory ENG VE 130 ...

Страница 131: ... clamp that fastens the cooling system s pipe to the starter motor s wir ing harness and the ground lead Insert the front left internal cable gland on the chassis and refit the wiring har nesses Connect the engine oil pressure bulb connector and refit the clamp that fas tens the wiring harness to it Tuono V4 1100 Factory Engine from vehicle ENG VE 131 ...

Страница 132: ...ew them partially to facilitate the subsequent op erations for the assembly of the ex haust system Connect the front bank lambda probe connector and engage it in its support Insert the radiators from the right side and engage the water radiator in the support on the left side CAUTION BEFORE FITTING THE RADIATORS MAKE SURE THEY ARE COMPLETELY EMPTY Engine from vehicle Tuono V4 1100 Factory ENG VE 1...

Страница 133: ...efit the wiring harnesses on the radi ator support and secure them with a new clamp Connect the coolant radiator pipe on the right side and secure it using the specific metal clamp Connect the oil pipe to the fitting and secure it using a new metal clamp Tuono V4 1100 Factory Engine from vehicle ENG VE 133 ...

Страница 134: ...adi ators support bracket and tighten them to the specified torque Secure the demand sensor wiring har ness to the expansion tank breather pipe using a new clamp Connect the breather pipe to the de mand sensor wiring harness using a cable gland and then place the pipe on the cable gland connected to the radi ator support bracket Engine from vehicle Tuono V4 1100 Factory ENG VE 134 ...

Страница 135: ...motor support Insert the two exhaust valve motor sup port fixing screws and tighten them to the specified torque Operating from the left side of the ve hicle secure the generator alternator wiring harnesses the oil pressure bulb the front bank lambda probe and the left electric fan using a new clamp Tuono V4 1100 Factory Engine from vehicle ENG VE 135 ...

Страница 136: ...onnector of the left side electric fan on the canister support Insert the two canister support fixing screws and tighten them to the speci fied torque Connect the oil pipe on the sump and secure it using a new metal clamp Insert the oil discharge plug fitted with a new sealing gasket and tighten it to the specified torque Engine from vehicle Tuono V4 1100 Factory ENG VE 136 ...

Страница 137: ...d insert it under the ABS modulator sup port as shown Insert the ABS modulator support at the back into the rubber ring Insert the screw that fastens the ABS modulator support to the chassis and the screw that fastens the metal plate to the support and then tighten them to the specified torque Tuono V4 1100 Factory Engine from vehicle ENG VE 137 ...

Страница 138: ...orm the valve ad justment procedure Insert 2 7 l 0 59 Uk gal and check the level in the expansion tank Insert 4 1 l 0 90 Uk gal of engine oil and check the level with the dipstick Connect the fuel tank the voltage regulator and battery Subsequently with the vehicle on the central stand start the engine and wait for the activation of the cooling fans Stop the engine check the oil and coolant levels...

Страница 139: ...INDEX OF TOPICS ENGINE ENG ...

Страница 140: ... rear left cylinder 2 front left cylinder 3 rear right cylinder 4 front right cylinder Combustion sequence 1 3 2 4 Combustion angle cyl 1 0 cyl 2 180 cyl 3 425 cyl 4 605 Engine Tuono V4 1100 Factory ENG 140 ...

Страница 141: ...38 lbf ft Vite pre impregnata e in assenza 3M SCOTCH GRIP 2353 3 Viti TE flangiate fissaggio flangia M8x25 6 25 Nm 18 44 lbf ft Lubrificare con olio 4 Special screw with index lever fas tening collar M6 1 10 Nm 7 38 lb ft Loct 243 5 Vite TE flangiata fissaggio pignone M10x35 1 50 Nm 36 88 lbf ft Loct 243 6 Vite di fermo preselettore su basa mento 1 25 Nm 18 44 lbf ft Vite pre impregnata e in assen...

Страница 142: ...ta marcia su primaria 7 Anello 8 Rosetta di spallamento 9 Gabbia a rulli per ingranaggio sesta marcia su primaria 10 Ingranaggio sesta marcia su primaria 11 Ingranaggio seconda marcia su primaria 12 Anello 13 Cuscinetto 14 Forchetta per albero primario 15 Albero forchetta 16 Molle per albero forchetta 17 Albero secondario 18 Cuscinetto a sfere 19 Pignone Engine Tuono V4 1100 Factory ENG 142 ...

Страница 143: ...ulli per ingranaggio quarta marcia su secondario 33 Rosetta di spallamento 34 Anello seeger 35 Ingranaggio quinta marcia su secondario 36 Rosetta 37 Ingranaggio prima marcia su secondario 38 Gabbia a rulli 39 Rosetta 40 Forchette per albero secondario 41 Albero forchetta 42 Molle per albero forchetta 43 Perno per selettore 44 Albero cambio 45 Gabbia a rulli 46 Piattello index 47 Cuscinetto a sfere...

Страница 144: ...using Remove the gear sensor from the flywheel side Remove the Seeger ring Remove the water oil pump control gear See also Removing the gear selector Disassembling the clutch Remove the water oil pump control gear driving pin Loosen the screw Engine Tuono V4 1100 Factory ENG 144 ...

Страница 145: ...ondary shaft from the alternator side to detach the gearbox cover from the crankcase Remove the complete gearbox unit Gearbox shafts Disassembling the gearbox Posizionare il cambio in folle verifican do che alla rotazione dell albero pri mario l albero secondario rimanga fer mo Rimuovere il gruppo cambio Sfilare l astina di comando albero pri mario cambio 1 Tuono V4 1100 Factory Engine ENG 145 ...

Страница 146: ...rk 2 of the gearbox pri mary shaft Slide off the gearbox secondary shaft control rod 3 Remove the forks 4 of the gearbox secondary shaft Remove both gearbox shafts from the cover Engine Tuono V4 1100 Factory ENG 146 ...

Страница 147: ...e shim washer 5 that is lo cated on the secondary shaft between the shaft and the cover Loosen and remove the screw 6 Remove the desmodromic shaft 7 Remove the selector drum 8 Tuono V4 1100 Factory Engine ENG 147 ...

Страница 148: ...omic gearbox control rod drum roller cage Lubricate the seat and insert the new roller cage Specific tooling 020863Y Punch assembly cage with rollers desmodromic drum Checking the primary shaft Characteristic Maximum wear limit for selector gear splines 5 3 mm 0 21 in Minimum wear limit of the pinion side primary shaft seat 24 97 mm 0 98 in Minimum wear limit of the clutch side primary and seconda...

Страница 149: ...nd wear and replace it if necessary Check the desmodromic bearing 2 for damage and pitting and replace it if necessary Characteristic Maximum selector shaft eccentricity 0 2 mm 0 0079 in Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears Characteristic Maximum endfloat of selector forks 0 05 mm 0 0020 i...

Страница 150: ...ace the gearbox forks if it is irregular Assembling the gearbox Place the drum 1 of the gear selector on the support and insert the desmo dromic shaft 2 paying attention to correspond the operations on both components Position and tighten the screw 3 fixing the drum to the desmodromic shaft CAUTION SECURE THE SHIM WASHER 4 TO THE SECONDARY SHAFT WITH GREASE Engine Tuono V4 1100 Factory ENG 150 ...

Страница 151: ...nto the support Grease the sliding bushes of the forks Insert the forks 5 in the specific seats of the gearbox secondary shaft Insert the gearbox secondary shaft control rod 6 checking the presence of the springs Tuono V4 1100 Factory Engine ENG 151 ...

Страница 152: ...gearbox primary shaft con trol rod 8 Position the special tool from the alter nator side in order to not ruin the edges of the oil seal Insert the gearbox unit in the crank case Specific tooling 0277308 Guide bushing for gearbox secondary shaft Engine Tuono V4 1100 Factory ENG 152 ...

Страница 153: ...pump shaft Install the water oil pump control gear Insert the Seeger ring Install the gear sensor making the pin coincide with the slot on the desmo dromic control rod Gear selector Removing the gear selector Drain the engine oil Remove the clutch cover Working from the clutch side remove the selector control shaft Remove the gear locking pawl and re trieve the washer and the spring Tuono V4 1100 ...

Страница 154: ...nch assembly cage with rollers gearbox control rod GEARBOX CONTROL ROD OIL SEAL AND ROLLER CAGE SPACER Remove the gearbox control rod spacer Remove the oil seal and the roller cage Install a new gearbox control rod roller cage on the spacer using the specific tool without an adaptor Specific tooling 020862Y Punch assembly cage with rollers gearbox control rod Position a new oil seal on the spacer ...

Страница 155: ... Check the selector shaft and its teeth for damage and wear If necessary replace the part Check the lever spring for damage and wear If necessary replace the part Reassembling the gear selector To refit lubricate and carry out the removal operations but in reverse order Starter motor Removing the starter motor Undo the fixing screws 1 of the starter motor collecting the spacers 2 Tuono V4 1100 Fac...

Страница 156: ...TER STARTING THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL Controllare la dentatura dell ingranaggio doppio di avviamento 1 e l ingranaggio ruota libera 2 per verificare la presenza di rotture nel materiale o de formazioni Per effettuare la rimozione dell ingranaggio ruota libera fare riferimento alla procedura Rimozione contralbero di equilibratura Engine Tuono V4 1100 Factory ENG 156 ...

Страница 157: ...r Make sure that the woodruff key slot is in perfect condition Remove the needle cage 3 and the roller cage 4 from their housings on the freewheel 2 and check the rollers needles for wear Check for wear on the freewheel sliding surface 2 Fitting the idle gear Fit the intermediate gear Fit the clutch cover Tuono V4 1100 Factory Engine ENG 157 ...

Страница 158: ...chio e di conseguenza viene rimossa la fascetta metallica nel rimontaggio utilizzare una nuova fascetta Svitare e rimuovere le cinque viti 3 e le tre viti speciali 4 prestando atten zione a recuperare le rosette di tenuta Contrassegnare le viti 3 in quanto hanno lunghezze differenti Rimuovere il coperchio 5 completo di statore recuperando i due grani di cen traggio Rimuovere il treebond dalle supe...

Страница 159: ...ere le tre viti del rac cordo impianto blow by Rimuovere il raccordo impianto blow by Rimuovere l o ring DURANTE LA FASE DI RIMONTAGGIO UTILIZ ZARE UN NUOVO ANELLO O RING Rimuovere l anello seeger Remove the shim washer Tuono V4 1100 Factory Engine ENG 159 ...

Страница 160: ...TO E NECESSARIO ALLAR GARE IL FORO CENTRALE QUANTO BASTA PER PERMETTERE L INSERIMENTO COM PLETO DEL VOLANO IL FISSAGGIO DEVE ESSERE GARANTITO MEDIANTE L UTILIZZO DELLE TRE VITI INDI CATE Svitare e togliere la vite Specific tooling 020914Y Flywheel stop Remove the tool for blocking flywheel rotation Insert a SHC M10x20 screw into the crankshaft hole which will act as a mounting base for flywheel ex...

Страница 161: ...o del motore See also Removing the flywheel cover Removing the stator Per procedere con la rimozione dello statore op erare come descritto Rimuovere le tre viti di fissaggio dello statore Rimuovere le due viti di fissaggio del pick up Rimuovere la piastrina di fermo del ca blaggio statore Tuono V4 1100 Factory Engine ENG 161 ...

Страница 162: ...re preventivamente la frizione completa Successivamente operare come descritto Posizionare l attrezzo specifico di fer mo dell ingranaggio primaria Specific tooling 020850Y Primary gear lock Svitare il dado di fissaggio dell ingra naggio primaria e il dado di fissaggio dell ingranaggio di comando contral bero Rimuovere l attrezzo di fermo ed es trarre l ingranaggio della primaria Specific tooling ...

Страница 163: ...from its housing and check the rollers for signs of wear Check if the outer spring is sufficiently preloaded to hold the rollers in place Check for wear on the sliding surface of the free wheel inside its housing IT IS NECESSARY TO REPLACE THE HOUSING OF THE FREE WHEEL IF DEFORMATIONS OR DEEP GROOVES ARE PRESENT ON THE SLIDING SURFACE Installing the flywheel Prima di procedere con l installazione ...

Страница 164: ...r inserito la vite di fissaggio completa di rondella serrare a coppia Specific tooling 020914Y Flywheel stop Flywheel cover components installation Se rimosso durante la fase di smontaggio utiliz zare un nuovo paraolio Per effettuare l installa zione è necessario utilizzare un apposito punzone Lubrificare la parte interna del paraolio e posizionarlo sul coperchio nel verso indicato Utilizzando l a...

Страница 165: ...osizionare l anello seeger Sostituire con uno nuovo dello stesso tipo l anello OR Posizionare il raccordo impianto blow by Inserire e serrare a coppia le tre viti del raccordo impianto blow by Tuono V4 1100 Factory Engine ENG 165 ...

Страница 166: ...dosi della pre senza delle rondelle 3 in tutte le viti Serrare le viti procedendo per stadi e in diagonale Position the soundproofing cover and lock it in place using the three appro priate screws Operando sulla base della cassa filtro collegare il tubo blow by e bloccarlo mediante una nuova molletta di fermo Utilizzare una nuova fascetta metallica se il tu bo blow by è stato rimosso dal raccordo ...

Страница 167: ...tare a coppia svitare e riportare a coppia 3 Vite TE flangiata M6x22 14 12 Nm 8 85 lbf ft Portare a coppia svitare e riportare a coppia 4 Tappo d ispezione fasatura motore 1 20 Nm 14 75 lbf ft 5 Distanziali per coperchio insonoriz zante 5 6 Nm 4 43 lbf ft 6 Asta livello olio 1 3 Nm 2 21 lbf ft 7 Tappo carico olio 1 5 Nm 3 69 lbf ft Tuono V4 1100 Factory Engine ENG 167 ...

Страница 168: ...m 110 63 lb ft Loct 243 2 Clutch springs SHC fixing screw M6x25 6 10 Nm 7 38 lb ft Removing the clutch cover Drain the engine oil Unscrew and remove the five special screws 1 to remove the soundproof cover 2 Svitare e rimuovere l astina livello olio motore Engine Tuono V4 1100 Factory ENG 168 ...

Страница 169: ...la guarnizione le due spine di centraggio e l ingranaggio di rinvio avviamento Disassembling the clutch Remove the clutch cover Unscrew and remove the six screws by loosening them 1 4 of a turn at a time operate in stages and diagonally and retrieve the washers and the clutch springs Remove the thrust plate and the com plete control rod Tuono V4 1100 Factory Engine ENG 169 ...

Страница 170: ...ell rotation using the spe cific tools Unscrew and remove the clutch bell fixing nut Specific tooling 020849Y Clutch retainer tool Rimuovere le due rosette e la molla a tazza Remove the clutch hub Engine Tuono V4 1100 Factory ENG 170 ...

Страница 171: ... Remove the clutch hub cam tower Rimuovere la rondella Rimuovere la campana frizione Remove the clutch gear that controls the oil water pumps Tuono V4 1100 Factory Engine ENG 171 ...

Страница 172: ...acteristic Maximum clutch plate deformation in compar ison to a flat surface 0 15 mm 0 0059 in Minimum wear limit of the clutch plate sliding teeth 13 5 mm 0 53 in Minimum wear limit of the complete clutch pack thickness friction discs steel discs 47 6 mm 1 87 in Engine Tuono V4 1100 Factory ENG 172 ...

Страница 173: ...if necessary replace the primary driven gear and the clutch bell all together Make sure there is not excessive noise during op eration if necessary replace the primary drive gear and the clutch bell all together Checking the pusher plate Check the thrust plate and the bearing for damage and wear If necessary replace the parts Characteristic Maximum deformation permitted on the thrust plate compres...

Страница 174: ... VALID FOR ALL CLUTCH SPRINGS Check the springs for signs of damage and replace them if necessary Measure the free length of the clutch springs and replace them if necessa ry Characteristic Minimum wear limit with individual clutch springs in release position 46 8 mm 1 84 in Assembling the clutch Insert the thrust bearing with the collar facing the gearbox Engine Tuono V4 1100 Factory ENG 174 ...

Страница 175: ...e cage Install the clutch gear making it mesh with the oil water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL Insert the clutch bell making it engage with the engine pinion Tuono V4 1100 Factory Engine ENG 175 ...

Страница 176: ...lla Install the clutch hub cam tower Position the clutch hub HOUSE THE THREE CLUTCH HUB CAMS IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES Inserire la molla a tazza e le due ro sette Engine Tuono V4 1100 Factory ENG 176 ...

Страница 177: ...ng nut Specific tooling 020849Y Clutch retainer tool Insert the disc with friction material and the black tooth into the bell Insert one of the metal discs into the bell Insert the flat washer Insert the spring washer with the con cave side facing out Tuono V4 1100 Factory Engine ENG 177 ...

Страница 178: ...rial into the housing Insert the nitrided metal disc into the clutch housing Continue inserting alternating a metal disc with one with friction material end ing with a friction material disc with a black tooth Engine Tuono V4 1100 Factory ENG 178 ...

Страница 179: ...ce the control rod together with the thrust bearing and the shim washer Place the thrust plate Fit the clutch springs 3 Insert the spring holder cap 2 onto the screws 1 Tuono V4 1100 Factory Engine ENG 179 ...

Страница 180: ... sufficiently Warm up the cover Using a generic extractor it is then possible to remove the bushing from the cover INSTALLING THE CLUTCH CONTROL PIN BUSHING Before carrying out the installation of the bushing it is necessary to warm up the cover Position the guide 1 to insert the bushing 2 as indicated in the figure Insert the bushing so that the process ing notch 3 is aligned with the notch on th...

Страница 181: ...wo dowel pins in the clutch cover Insert the clutch cover making sure to have correctly engaged the clutch con trol lever and the rack shaft Insert the five special screws 5 and the eleven fastening screws 6 around the perimeter taking care to also insert the relative washers Tighten the screws working in stages and diagonally Inserire e avvitare l astina livello olio motore Tuono V4 1100 Factory ...

Страница 182: ...ppia Ripristinare l olio motore verificando il corretto quantitativo Heads VALVES COVER Pos Description Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 38 lb ft 2 TE flanged coil fixing screw M6x12 4 8 Nm 5 90 lb ft Loct 243 3 Spark plugs 4 12 Nm 8 85 lb ft Engine Tuono V4 1100 Factory ENG 182 ...

Страница 183: ...e covers fixing screws 6 6 Nm 4 43 lb ft 4 Water outlet coupling fixing screw 2 10 Nm 7 38 lb ft Pre impregnated or else Loct 270 or Loct 648 5 Flanged head nut 12 30 55 Nm 22 13 40 57 lb ft Lubricate the head and under the head 6 Head tightening screw chain side M6x55 4 12 Nm 8 85 lb ft Lubricate the head and under the head Tuono V4 1100 Factory Engine ENG 183 ...

Страница 184: ...43 2 Chain tensioner sliders fastening screws M8 2 20 Nm 14 75 lb ft Loct 243 3 Chain guide sliders fixing screws M6x18 2 10 Nm 7 38 lb ft Loct 243 Head cover removal Le operazioni che seguono si riferiscono ad una testa ma solo valide per entrambe Svitare e rimuovere le tre viti con rela tive rondella in gomma Engine Tuono V4 1100 Factory ENG 184 ...

Страница 185: ...Smear the head surface with suitable sealant in the area indicated in the fig ure Recommended products Three bond Sealing paste Fit the head cover Tighten the three screws with rubber washers to the prescribed tightening torque Valves Valve removal Remove the head Place the head on supporting surface Number the valves and their bucket tappets in order to position them correctly upon refitting Tuon...

Страница 186: ...ific wrench and with the spring compressing tool Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs See also Front head removal Rear head removal Remove the cotters using a magnet Engine Tuono V4 1100 Factory ENG 186 ...

Страница 187: ... REPLACE THE VALVES ONE AT A TIME DO NOT MIX THE COMPONENTS EACH VALVE MUST BE INSERTED INTO ITS SEAT WHICH IS MARKED PRIOR TO REMOVAL VALVE STEM DEVIATION Lift up the valve approx 10 mm 0 39 in from its seat Measure the valve stem deviation in two perpen dicular directions and position the dial gauge as shown in the figure Characteristic Valve stem distortion Tuono V4 1100 Factory Engine ENG 187 ...

Страница 188: ... 1959 0 1951 in Support the valve with two V blocks as shown and check the run out with a dial gauge If the run out exceeds the specified limit replace the valve Characteristic Valve stem run out 0 05 mm 0 0020 in Position the dial gauge at a right angle to the valve head face and measure the eccentricity If the eccentricity exceeds the specified limit re place the valve Characteristic Valve head ...

Страница 189: ...al colore blu 1 mentre quelle di scarico 2 sono contrassegnate dal colore giallo Lubricate the valve stem and insert the valves on the valve guide Position the springs with the closest turns facing the head of the valve CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE AS THE EXHAUST VALVES HAVE A SINGLE SPRING Fit the caps Tuono V4 1100 Factory Engine ENG 189 ...

Страница 190: ...eat Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs Release the wrench checking that the cotters are positioned correctly in the valve grooves Position the adjusting shims Position the bucket tappets Engine Tuono V4 1100 Factory ENG 190 ...

Страница 191: ...d TE screw fixing fuel rail gearbox lubrication M6x12 2 10 Nm 7 38 lb ft Pre impregnated screw and in ab sence Loct 2045 8 TB TORX fixing screw of the con necting rods lubrication nozzles 4x12 4 5 Nm 3 69 lb ft Pre impregnated screw in absence Loct 2045 9 TSPEI screw fixing bearing stop plates M6x16 2 10 Nm 7 38 lb ft Loct 243 10 Stud bolt M6 1 Bring to 33mm from the surface Loct 648 11 SHC screw ...

Страница 192: ... 2 6 Nm 4 43 lb ft IGNITION UNIT Pos Description Type Quantity Torque Notes 1 Hex headed nut cl 10 type 2 iso 8674 M10x1 1 50 Nm 36 88 lb ft Loct 243 2 Starter motor SHC fastener screw M6x40 2 10 Nm 7 38 lb ft Screw fastening cables to the starter motor M6 1 6 Nm 4 43 lb ft Engine Tuono V4 1100 Factory ENG 192 ...

Страница 193: ...lbf ft Vite preimpregnata e in assenza Loct 2045 5 Viti fissaggio piastrina di fermo pick up 2 6 Nm 4 43 lbf ft Vite preimpregnata e in assenza Loct 2045 Balancing countershaft removal Per effettuare la rimozione del contralbero di equi libriatura è necessario rimuovere preventivamente il coperchio frizione il coperchio alternatore e la frizione completa Successivamente operare come descritto Posi...

Страница 194: ...di fermo ed es trarre l ingranaggio della primaria Specific tooling 020850Y Primary gear lock Rimuovere la rondella ed estrarre l ing ranaggio di comando contralbero in granaggio ruota libera prestando at tenzione a non far cadere all interno del motore la chiavetta Rimuovere la chiavetta dal contral bero Engine Tuono V4 1100 Factory ENG 194 ...

Страница 195: ...ttuare l installazione del contralbero di equilibratura eseguire le operazioni di seguito de scritte Inserire il contralbero di equilibratura nel carter dal lato volano Operando dal lato frizione inserire il distanziale sul contralbero verificando l orientamento come rappresentato Tuono V4 1100 Factory Engine ENG 195 ...

Страница 196: ... ta CAUTION ASSICURARSI DEL CORRETTO POSIZIONAMENTO DEL LA CHIAVETTA CHE DEV ESSERE COME INDICATO Inserire la rondella e il dado di fissaggio dell ingranaggio di comando contral bero CAUTION ASSICURARSI DEL CORRETTO POSIZIONAMENTO DEL LA CHIAVETTA CHE DEV ESSERE COME INDICATO Posizionare l attrezzo specifico di fer mo dell ingranaggio primaria Dopo aver inserito il dado di bloccaggio della primari...

Страница 197: ...ar lock Svitare e rimuovere il dado di fissaggio dell ingranaggio primaria Rimuovere l attrezzo di fermo ed es trarre l ingranaggio della primaria Specific tooling 020850Y Primary gear lock Installing the primary drive gear Per effettuare l installazione dell ingranaggio della primaria eseguire le seguenti operazioni Inserire l ingranaggio della primaria sull albero motore prestando atten zione ad...

Страница 198: ...ing components alternator water pump gearbox unit primary drive shaft gear both timing chains the chain sliders oil sump the gear selector pin spacer starter motor and intermediate gear countershaft See also Magneto flywheel removal Water pump Disassembling the gearbox Main transmission gear removal Front head removal Rear head removal Removing the oil sump Balancing countershaft removal Engine Tu...

Страница 199: ...ward and loosen the screws in the following order 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 After loosening all screws remove them in order indicated above Loosen the six nuts on the stud bolts proceeding in the following order 6 5 4 3 2 1 After loosening all nuts remove them in order indicated above Tuono V4 1100 Factory Engine ENG 199 ...

Страница 200: ... heads Open the crankcases Install the tool that keeps the crank shaft in position Specific tooling 020857Y Crankshaft support U bolt Unscrew and remove the two connect ing rod screws Remove the connecting rod cap NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the piston connected to the connecting rod from the cylinder side Take out the Seeger ring Engine Tuono V4 1100 Factory EN...

Страница 201: ...eads were removed position the specific special tool to keep the pis tons from coming out Specific tooling 020858Y Maintenance of the pistons in the cyl inders Unscrew and remove the eight con necting rod screws Remove the four connecting rod caps NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Tuono V4 1100 Factory Engine ENG 201 ...

Страница 202: ...ove the countershaft FLYWHEEL SIDE Unscrew and remove the bearing re tainer screw Remove the lock Heat up the crankcase to 150 C 302 F Position the general tool to pull out bearings Remove the bearing CLUTCH SIDE Unscrew and remove the bearing re tainer screw Remove the lock Engine Tuono V4 1100 Factory ENG 202 ...

Страница 203: ...haracteristic Maximum crankshaft axial clearance after closing the crankcase 0 5 mm 0 0197 in Maximum radial clearance between the main bearings and the crankshaft pins 0 07 mm 0 00276 in Balancing countershaft check Characteristic Maximum countershaft axial clearance after closing the crankcase 0 1 mm 0 0039 in Tuono V4 1100 Factory Engine ENG 203 ...

Страница 204: ...0 027 0 045 mm 0 025 0 043 mm CAUTION THE MEASUREMENT OF THE PISTON DIAMETER IS PER FORMED AT 6 mm 0 24 in FROM ITS BASE Characteristic Coupling clearance between the pin and the hole on the piston 0 016 0 005 mm 0 0006 0 0002 in Aperture tolerance of the first piston ring mounted on the cylinder 0 10 0 25 mm 0 0039 0 0098 in Aperture tolerance of the second piston ring mounted on the cylinder 0 4...

Страница 205: ...sted in the following table CRANKSHAFT CONNECTING ROD BALANCING CLASSES Crankshaft balancing classes Combinations of weight classes for connecting rod pair on alternator side Combinations of weight classes for connecting rod pair on primary drive side AA AA AA AA AA BB BB BB AA CC BB BB AA CC CC CC CC BB DD CC CC DD BB DD DD DD CC EE DD DD EE CC EE EE EE EE EE paired selections of mountable weight...

Страница 206: ...ses are available A B C which differentiate in the diameter of the hole in the bearings The category is marked on the crankcase on the right side in the area below the gearbox Different classes of bearings can be used e g A B C or B B C or A B A A number that indicates the position of the main journal is stamped on the crankcase 1 flywheel side 2 central 3 clutch side Engine Tuono V4 1100 Factory ...

Страница 207: ...asses CRANKSHAFT CATEGORIES Specification Desc Quantity Class C Main journals diameter 46 028 46 023 mm 1 8121 1 8119 in Class D Main journals diameter 46 023 46 018 mm 1 8119 1 8117 in Class E Main journals diameter 46 018 46 013 mm 1 8117 1 8115 in Once the categories below are checked 1 crankcase 2 flywheel side main journal 3 centre main journal 4 clutch side main journal Choose the bushings u...

Страница 208: ...rnal Bushing yellow Bushing yellow Bushing blue Class D main journal Bushing green Bushing yellow Bushing yellow Class E main journal Bushing green Bushing green Bushing yellow CRANKSHAFT BUSHINGS CONNECTING RODS Three types of semi bushing are available for the connecting rods Engine Tuono V4 1100 Factory ENG 208 ...

Страница 209: ...Required clearances class 2 X 35 885 35 880 mm Blue Yellow 1 Yellow Yellow 0 053 0 026 mm 0 053 0 027 mm Y 35 880 35 874 mm Yellow Yellow Yellow Green 1 0 054 0 026 mm 0 054 0 027 mm Z 35 874 35 869 mm Yellow Green 1 Green Green 0 054 0 027 mm 0 054 0 028 mm Key 1 If using bushing of different thickness install the thickest on the side of the connecting rod shank BIG END BUSHING REPLACEMENT PROCED...

Страница 210: ...diametro maggiore rivolto verso l esterno del motore Inserire l ingranaggio della primaria sull albero motore prestando atten zione ad allinearlo con l ingranaggio di comando del contralbero Tale allinea mento è determinato dall intersezione delle bulinature presenti nei due ingra naggi NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE ...

Страница 211: ... pistons have two selections A and B Therefore they are coupled with the cylinder ac cording to the selection of the latter which is marked on the upper crankcase halves Pre assemble the pistons on the workbench with the connecting rod shank and the relative semi bushing The pre assembly procedure is identical for all four pistons and must be done as follows with the piston crown parallel to the w...

Страница 212: ...pi stone rivolta verso lo scarico lo smus so sulla testa di bielle deve essere rivolto verso l esterno del proprio perno di manovella Specific tooling 020980Y Piston assembly ring Remember to couple the connecting rod shank and cap correctly combin ing the respective numerical referen ces Use new connecting rod screws lubri cating the thread and under the head Proceed with tightening according to ...

Страница 213: ...dowels in the crankcase Insert a new oil seal O ring in the spe cific seat Insert the maximum pressure valve in the crankcase composed of two sep arate parts Apply a layer of sealing paste along the external edge of the crankcase Join the two crankcases Recommended products Three bond Sealing paste Tuono V4 1100 Factory Engine ENG 213 ...

Страница 214: ...he following order 1 2 3 4 5 6 Then tighten them fully following the same order Pre tighten the screws in the following order 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Then tighten them fully following the same order Engine Tuono V4 1100 Factory ENG 214 ...

Страница 215: ...lb ft Tighten to torque unscrew and re tighten to torque 4 Oil pipes coupling fastening screw M6 1 10 Nm 7 38 lb ft Loctite 243 5 Screws used to fasten the pump to the crankcase M6 5 10 Nm 7 38 lb ft 6 Oil pressure sensor fastening 1 15 Nm 11 06 lb ft 7 Oil filter fastening 1 15 Nm 11 06 lb ft 8 Screws used to fasten the pump to the crankcase M6 1 10 Nm 7 38 lb ft 9 Oil return pipe fastening screw...

Страница 216: ...the head and under the head 5 Crankcase fastening screws M8 3 25 Nm 18 44 lb ft Lubricate with oil Lubricate the head and under the head 6 Crankcase fastening screw M8 1 25 Nm 18 44 lb ft Lubricate with oil Lubricate the head and under the head 7 Crankcase fastening screws M6 8 10 Nm 7 38 lb ft Lubricate the head and under the head 8 Crankcase fastening screw M6 1 10 Nm 7 38 lb ft Lubricate the he...

Страница 217: ...TION IT IS IMPOR TANT TO CHECK THAT THE OIL DELIVERY HOLES ARE NOT BLOCKED To remove the lubrication jets simply remove the retaining screw and then extract them from their housings tak ing care not to lose the rubber O ring To remove the lubrication pipe simply remove the retaining screws and then extract it from its housing taking care not to lose the rubber O ring Oil pump Removing Remove the g...

Страница 218: ...oving the gearbox Water pump Unscrew and remove the four cooling oil pump cover screws Remove the cooling oil pump cover Collect the two dowel pins Remove the external rotor from the cover Remove the internal oil cooling rotor Collect the hitch pin Engine Tuono V4 1100 Factory ENG 218 ...

Страница 219: ...rews Remove the lubrication oil pump cover and the intermediate pump casing from the shaft Collect the two dowel pins Remove the external lubrication rotor Remove the internal oil lubrication ro tor Collect the drive spindle Tuono V4 1100 Factory Engine ENG 219 ...

Страница 220: ...om the side with the Seeger ring seat for fasten ing the gear Install the drive spindle on the shaft Position the external rotor on the lubri cation pump s internal rotor Position the dowel pins Position the pump cover and the inter mediate pump casing on the lubrica tion pump s external rotor To check that the intermediate casing is oriented correctly check the gasket seat Engine Tuono V4 1100 Fa...

Страница 221: ... pump control shaft Position the oil cooling pump s internal rotor Position the dowel pins and the exter nal rotor on the cooling oil pump cover Fit the pump cover on the internal rotor Tighten the four cooling oil pump cover screws Fit a new gasket Tuono V4 1100 Factory Engine ENG 221 ...

Страница 222: ...f the countershaft 1 to separate the engine oil into oil vapour and liquid The oil vapours exit from the fitting 2 on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump Engine Tuono V4 1100 Factory ENG 222 ...

Страница 223: ...gram Valve controlled by control unit which delivers as pirated air from the filter box to the exhaust mani folds The advantages of this function are twofold the catalytic converter reaches the op erating temperature more quickly it permits the use of richer mixtures in some critical conditions e g at idle or low engine speeds Tuono V4 1100 Factory Engine ENG 223 ...

Страница 224: ...Inspecting the one way valve Unscrew and remove the three screws Remove the cover together with the two secondary air system valves Engine Tuono V4 1100 Factory ENG 224 ...

Страница 225: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Страница 226: ...ndi il corretto funzionamento Removing the throttle body Completely remove the air filter box Disconnect the injector fuel pipe Release the snap fit clamp on the col lars from the engine NOTE DO NOT RELEASE THE CLAMPS COMPLETELY LEAVE IN AN INTERMEDIATE POSITION TO FACILITATE REFIT TING Disconnect the lower injector connec tors Disconnect the connector Remove the complete throttle body See also Ai...

Страница 227: ...ssible before replacing the com ponent is checking the connectors and cable har nesses Installing the throttle body When installing the throttle body refer to the electrical system section for the correct cable routing Ensure that the injector connectors are correctly fastened Connect the control unit connector en suring that the security lock is in the locked position Stepper motor The control un...

Страница 228: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Страница 229: ...is equipped with An upper adjustment screw 2 to set the hydraulic compression braking An upper nut 3 to adjust the spring preload TO AVOID DAMAGE DO NOT FORCE THE ADJUSTERS BEYOND THE MAXIMUM SETTING POSITION IN EITHER DIRECTION SET THE SAME SPRING PRE LOAD AND HY DRAULIC DAMPING SETTING FOR BOTH STANCHIONS RIDING THE VEHICLE WITH DIFFERENT SETTINGS FOR THE TWO STANCHIONS REDUCES STABILITY WHEN SP...

Страница 230: ...s described in detail at paragraph a PRC SYSTEM under the ASC section To adjust the spring pre load discon nect the connector 1 from the elec tronic forks to be able to reach the adjustment nut 2 located on the cap TO AVOID DAMAGING THE CONNECTOR PRESS THE TAB 3 ON THE INDICATED POINT AND THEN CAREFUL LY REMOVE THE CONNECTOR PAY SPECIFIC ATTENTION WHEN DISCONNECTING THE CONNECTORS TO AVOID DAMAGIN...

Страница 231: ... Dealer Removing the fork legs Per effettuare la rimozione degli steli è necessario posizionare il motociclo su appositi cavalletti di sostegno scollegare le pinze freno anteriori ri muovere il parafango la ruota anteriore le care nature laterali e la carrozzeria anteriore LE OPERAZIONI CHE SEGUONO SONO RI FERITE AD UNO STELO MA SONO VALIDE PER ENTRAMBI SOLO PER LA VERSIONE CON SOSPENSIONI ELETTRO...

Страница 232: ... the degree to which they protrude following the instructions provided in the Settings paragraph in the Suspensions section Draining oil TUONO V4 1100 NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS Using the appropriate tool fasten the fork in the vice Specific tooling AP8140149 Guard for assembly operations Suspensions Tuono V4 1100 Factory SUSP 232 ...

Страница 233: ...king it in a vice by the specific tool Completely unscrew the plug Specific tooling AP8140149 Guard for assembly operations Using the specific tool fixed to the pre load pipe compress the spring Insert a spanner in the lock nut of the cover Specific tooling 020888Y Pre load pipe clamp Tuono V4 1100 Factory Suspensions SUSP 233 ...

Страница 234: ... Unscrew the cap and remove it Remove the spring pre load pipe Remove the lock nut and the washer Remove the spring paying attention to drain the oil correctly Suspensions Tuono V4 1100 Factory SUSP 234 ...

Страница 235: ...OLLOWING OPERATIONS REFER TO THE OHLINS FORKS Set the pre loading spring to the mini mum position Unscrew the upper cap from the sleeve using a specific Öhlins tool Specific tooling 01761 04 Ohlins fork cap ring nut Loosen the cap using a wrench in order to release the upper nut on the spring retaining ring Unscrew the upper adjustment cap us ing the special Ohlins tool Specific tooling 01761 04 O...

Страница 236: ...complete cap Unscrew the nut and remove it exert ing slight pressure on the pre loading spring Remove the pre loading spring retain ing ring Remove the pre loading spring Suspensions Tuono V4 1100 Factory SUSP 236 ...

Страница 237: ...Discharge the fork remove the internal dipstick of the pumping member pin 1 and the washer 2 Operate repeatedly on the pumping member pin 3 so as to drain com pletely the oil from inside Slide off the dust scraper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim Remove the retainer ring Tuono V4 1100 Factory Suspensions SUSP 237 ...

Страница 238: ...move the lock seeger ring of the spring guide Remove the spring guide Using a hook spanner lock the pump ing member pin Remove the stem bottom screw Specific tooling 020889Y Wrench for locking pumping unit ring nut Remove the pumping member pin TUONO V4 1100 FACTORY NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS FORKS Suspensions Tuono V4 1100 Factory SUSP 238 ...

Страница 239: ... the wheel holder shaft 1 and the sleeve 2 Clamp the sleeve in a vice and by lev ering it alternately at various points remove the anti dust seal 3 from the sleeve 2 Remove the retaining ring 4 Tuono V4 1100 Factory Suspensions SUSP 239 ...

Страница 240: ...INING IT WHILE REMOVING THE SHAFT SEAL 5 Replace the following components with new ones shaft seal 5 anti dust seal 3 CAUTION PROCEED WITH EXTREME CAUTION IN ORDER TO PREVENT FOREIGN BODIES FROM EN TERING THE SLEEVE OR THE WHEEL HOLDER SHAFT DO NOT REUSE THE OIL THAT WAS DRAINED EARLIER Suspensions Tuono V4 1100 Factory SUSP 240 ...

Страница 241: ...t 193 195 198 203 Crankcase 191 199 203 213 Crankshaft 201 203 210 Cylinder 50 56 D Desmodromic drum 149 Drive chain 19 E ECU Electrical system 7 19 71 73 Engine oil 37 Exhaust 97 F Fork 229 231 237 Forks 149 Front cylinder head valves 50 Front head 186 198 201 Fuel Fuses 82 H Head cover 184 Headlight 68 I Identification 17 K Keys 80 M Magneto flywheel 160 198 ...

Страница 242: ...ar cylinder head valves 56 Rear head 186 198 201 Recommended products 34 S Scheduled maintenance 32 Secondary air system Secondary shaft 149 Spark plug 35 Start up 156 Starter motor 155 Stepper motor 227 T Throttle body 226 227 Track Transmission 18 197 198 Tyres 21 U Use W Water pump 198 218 Wiring diagram 76 ...

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