APRILIA TUONO 1000 R Instruction manual

www.serviceaprilia.com
workshopmanual
TUONO 1000
1306 5
12/2005-00
8104982 UK

INTRODUCTION
0 - 1
TUONO 1000
INTRODUCTION 0

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

INTRODUCTION
0 - 3
TUONO 1000
0.1. FOREWORD
0.1.1. FOREWORD
- This manual provides the information required for normal servicing.
- This publication is intended for use by aprilia Dealers and their qualified mechanics; certain information has been
omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. Since
complete mechanical explanations have not been included in this manual, the reader must be familiar with basic
notions of mechanics, as well as with basic repair procedures. Repairing or inspecting a motorcycle when one does
not possess such basic knowledge or training could result in improper servicing and make the motorcycle unsafe to
ride. For the same reason, certain basic precautions have been omitted in the descriptions of repair and inspection
procedures; you are therefore invited to take special care to avoid damage to motorcycle components or injury to
persons. aprilia s.p.a. undertakes to constantly improve the design of its products and the relevant literature to
ensure maximum customer satisfaction. The main technical modifications and changes 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 vehicle.
aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the
essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
The mention of third parties’ products is only made for information purposes, and constitutes no engagement.
aprilia s.p.a. is not liable in any way for the performance or use of these products.
First edition: December 2005
Produced and printed by:
VALLEY FORGE DECA
Ravenna, Modena, Turin
DECA s.r.l.
via Vincenzo Giardini, 11
48022 Lugo (RA) - Italy
Tel. +39 - 0545 216611
Fax +39 - 0545 216610
E-mail: [email protected]
www.vftis.com
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com

INTRODUCTION
0 - 4
TUONO 1000
0.1.2. REFERENCE MANUALS
PARTS CATALOGUES
aprilia part# (description)
3985
SPECIAL TOOLS MANUALS
aprilia part# (description)
001A00
OWNER'S MANUALS
aprilia part# (description)
8104927
8104928
8104929
8104930
CHASSIS WORKSHOP MANUAL
aprilia part# (description)
8104978
8104981
8104979
8104980
8104982
8104983
ENGINE TECHNICAL MANUAL
aprilia part# (description)
8140743
8140744
8140745
8140746
8140747
8140748

INTRODUCTION
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TUONO 1000
0.1.3. ABBREVIATIONS / SYMBOLS
# = number
< = less than
> = greater than
≤= less than or equal to
≥= greater than or equal to
~ = approximately
∞= infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
± = plus or minus
A.C. = alternating current
A = Ampere
Ah = Ampere per hour
API = American Petroleum Institute
AT = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement unit (1 bar = 100 kPa)
D.C. = direct current
cc = cubic centimetres
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
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
SIDE = left side
m/s = metres per second
max = maximum
mbar = millibar (1 mbar = 0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")
MΩ= MegaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton metre (1 Nm = 0.1 kgm)
Ω= ohm
PICK-UP = pick-up
BDC = Bottom Dead Centre
TDC = Top Dead Centre
PPC = Pneumatic Power Clutch

INTRODUCTION
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TUONO 1000
RIGHT
SIDE = right 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

GENERAL INFORMATION
1 - 1
TUONO 1000
GENERAL INFORMATION 1

GENERAL INFORMATION
1 - 2
TUONO 1000
SUMMARY
1.1. STRUCTURE OF THE MANUAL..................................................................................................................... 3
1.1.1. CONVENTIONS USED IN THE MANUAL ............................................................................................. 3
1.1.2. SAFETY WARNINGS............................................................................................................................. 4
1.2. GENERAL RULES........................................................................................................................................... 5
1.2.1. BASIC SAFETY RULES......................................................................................................................... 5
1.3. DANGEROUS ELEMENTS ............................................................................................................................. 8
1.3.1. WARNINGS ........................................................................................................................................... 8
1.4. RUNNING-IN ................................................................................................................................................. 11
1.4.1. RUNNING-IN........................................................................................................................................ 11
1.5. VEHICLE IDENTIFICATION.......................................................................................................................... 12
1.5.1. POSITION OF THE SERIAL NUMBERS ............................................................................................. 12

GENERAL INFORMATION
1 - 3
TUONO 1000
1.1. STRUCTURE OF THE MANUAL
1.1.1. CONVENTIONS USED IN THE MANUAL
•This manual is divided in sections and subsections, each covering a set of the most significant components. For
quick reference, see the summary of sections.
•Unless expressly specified otherwise, assemblies are reassembled by reversing the assembly procedure.
•The terms "right" and "left" 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:
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Finland Japan United
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Belgium Singapore Brazil
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France Israel New
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