APRILIA TUONO R FACTORY 2007 Guide

SERVICE STATION MANUAL
854104
TUONO R_FACTORY

SERVICE STATION
MANUAL
TUONO R_FACTORY
The descriptions and illustrations given in this publication are not binding; While the basic characteristics
as described and illustrated in this manual remain unchanged, aprilia reserves the right, at any time and
without being required to update this publication beforehand, to make any changes to components, parts
or accessories, which it considers necessary to improve the product or which are required for
manufacturing or construction reasons.
Notallversionsshowninthispublicationareavailableinallcountries.Theavailabilityofindividualmodels
should be confirmed with the official aprilia sales network.
© Copyright 2008 aprilia. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. aprilia - After-sales service.
aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL
TUONO R_FACTORY
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sectionsmarked withthis symbolindicate the correct use ofthe vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
CLUTCH SYSTEM CLU SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

Rules
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
CAUTION
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THEENGINESWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUELVAPOUR.
AVOIDANY CONTACT WITH NAKEDFLAME, SPARKSOR OTHER HEATSOURCES WHICHMAY
CAUSE IGNITION OR EXPLOSION.
DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN.
Hot components
The engine and the exhaust system components become very hot and remain hot for some time 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 coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE CARE NOT TO SPILL COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPO-
NENTS; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE FLAME. WHEN CARRYING
OUT MAINTENANCE, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN THOUGH IT IS TOXIC,
COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEV-
ER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS
THEY MAY DRINK IT.
Characteristics TUONO R_FACTORY
CHAR - 6

KEEP OUT OF THE REACH OF CHILDREN.
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
PRESSURISED AND MAY CAUSE SCALDING.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN.
Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS
WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE
SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN
THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH
PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH 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 IMPORTANT TO PROTECT YOUR EYES BECAUSE
EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IN THE EVENT OF CON-
TACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CON-
SULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED,
DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR
VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EX-
PLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER
HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING
THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY BEING ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
TUONO R_FACTORY Characteristics
CHAR - 7

When repairing, dismantling and reassembling the vehicle follow the recommendations reported below
carefully.
BEFORE REMOVING COMPONENTS
•Beforedismantling components, removedirt, mud,dust andforeign bodiesfrom thevehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•Donot loosenand/or tightenscrews and nuts using pliersor anyother toolsthan thespecific
wrench.
•Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and
identify them with different distinctive symbols.
•Each component needs to be clearly marked to enable identification during reassembly.
•Clean and wash the dismantled components carefully using a low-flammability detergent.
•Keep mated parts together since they have "adjusted" to each other due to normal wear.
•Some components must be used together or replaced altogether.
•Keep away from heat sources.
REASSEMBLY OF COMPONENTS
CAUTION
BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH-
ERWISE, THEY NEED TO BE REPLACED.
•Only use ORIGINAL Aprilia SPARE PARTS.
•Comply with lubricant and consumables use guidelines.
•Lubricate parts (whenever possible) before reassembling them.
•Whentightening nuts andscrews,start eitherfrom thecomponentswiththe largestdiameter
or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-
cessive steps before applying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new parts if the thread is damaged.
•When assembling the bearings, make sure to lubricate them well.
•Check that each component is assembled correctly.
•After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on
private grounds or in an area with low traffic.
•Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of
lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand
or batch number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the cable harness:
Press the relevant safety hooks, if any.
Characteristics TUONO R_FACTORY
CHAR - 8

•Grip the two connectors and disconnect them by pulling them in opposite directions.
•If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
•Ensure that the cables are correctly fastened to the internal connector terminals.
•Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY
ROUND.
TIGHTENING TORQUES
CAUTION
IN THE EVENT THAT A SELFBRAKING NUT IS UNSCREWED, IT IS NECESSARY TO REPLACE
IT WITH A NEW ONE.
CAUTION
DO NOT FORGET THAT THE TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON
WHEELS, BRAKES, WHEEL BOLTS AND ANY OTHER SUSPENSION COMPONENTS PLAY A
KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM-
PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET
LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE
VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR
DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients
are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the run-
in. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the
engine components to cool.
CAUTION
THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON
SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH DISCS
GET ADAPTED.
ITIS IMPORTANT TOSTRAINENGINECOMPONENTS DURING RUN-IN,HOWEVER,MAKESURE
NOT TO OVERDO THIS.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow the guidelines detailed below:
•Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
•During the first 100 km (62 miles) brake carefully to avoid rough and long braking. That is
to permit the adequate adjustment of the pad friction material to the brake discs.
TUONO R_FACTORY Characteristics
CHAR - 9

•During the first 1000 km (620 miles), never exceed 6000 rpm.
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE
CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE
SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
•Between 1000 km (625 miles) and 1500 km (932 miles) travelled, ride more vigourously,
vary speeds and twist throttle fully for some short periods for best coupling of the compo-
nents; do not exceed 7500 rpm.
•After 1500 km (932 miles) a better engine performance may be expected but without ex-
ceeding the engine maximum rpm [11000 rpm].
Vehicle identification
Write down the chassis and engine number in the specific space in this booklet. The chassis number
is handy when purchasing spare parts.
CAUTION
THE MODIFICATION OF THE IDENTIFICATION CODES IS A SERIOUS PUNISHABLE CRIME.
HOWEVER, THE LIMITED WARRANTY FOR NEW VEHICLES WILL BE VOID IF THE VEHICLE
IDENTIFICATION NUMBER (VIN) HAS BEEN MODIFIED OR NOT PROMPTLY DETERMINED.
ENGINE NUMBER
The engine number is printed on the base of the
engine crankcase, left hand side.
Engine No. ....................
CHASSIS NUMBER
The chassis number is stamped on the right side of the headstock.
Chassis No. ....................
Dimensions and mass
DIMENSIONS
Specification Desc./Quantity
Max. length 2025 mm (79.72 in)
Max. width 830 mm (32.68 in)
Max. height (to top fairing) 1100 mm (43.31 in)
Saddle height 810 mm (31.89 in)
Centre to centre distance 1410 mm (55.51 in)
Minimum ground clearance 150 mm (5.91 in)
Characteristics TUONO R_FACTORY
CHAR - 10

Specification Desc./Quantity
Kerb weight R 209 kg ( 461 lb) - FACT. 205 kg (452 lb) (with forged wheels,
aluminium bolt and carbon bodywork parts)
Engine
ENGINE
Specification Desc./Quantity
Model V990RR NG
Type 60° longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 over-
head camshafts.
No. of cylinders 2
Overall engine capacity 997.6 cm³ (60.88 cu.in)
Max. nominal power (to crankshaft) 102 kW (137 HP) at 9500 rpm
Max. torque 107 Nm (10.7 kgm) at 7750 rpm
Bore / stroke 97 mm / 67.5 mm (3.82 in / 2.66 in)
Compression ratio 11.8 +/- 0.5 :1
Camshaft intake 266°, valve lift = 11.8 mm (0.465 in)
Camshaft outlet 259°, valve lift = 10.6 mm (0.417 in)
Valve advance - with 1 mm (0.039 in) valve clearance Intake opening = 25° before the TDC
Intake closing = 61° after the BDC
Outlet opening = 64° before the TDC
Outlet closing = 15° after the BDC
Intake valve clearance 0.11 - 0.18 mm (0.0043 - 0.0071 in)
Valve clearance at outlet 0.22 - 0.29 mm (0.0087 - 0.0114 in)
Electric Electric starter
Engine revs at idle speed 1250 +/- 100 rpm
Engine revs at maximum speed 11000 ± 100 rpm
Ignition electronically controlled ignition system
Ignition advance at start-up: 5° before TDC, further advance depending on con-
sumption levels
Starter motor gear ratio I = 49/9 * 30/11 * 64/30 = 31.677
Clutch Multiple disks in oil bath with hydraulic control on the left side
of the handlebar and PPC device
•9 lined discs; thickness: 3.5 mm (0.138 in)
•10 internal discs; thickness: 1.5 mm (0.059 in)
Lubrication system Dry sump system with separate oil tank and cooling radiator
Lubrication pressure Min. 350 kPa (3.5 bar)
At 80°C (176°F) and 6000 rpm max.
Air filter With dry cartridge filter
Cooling Fluid
Coolant pump gear ratio Iwp = 28/27 * 28/28 = 1.037
Coolant pump capacity (with thermostatic valve open) 100 l/min (26.4 USgal/min) (22 UKgal/min) at 9000 rpm
Temperature when thermostatic valve starts to open 65 ± 2 °C (149 ± 5 °F)
Engine dry weight approx. 67 kg (147.7 lb)
Transmission
GEARBOX
Specification Desc./Quantity
Type Mechanical, 6 speeds with foot lever on the left hand side of
the engine
GEAR RATIO
Specification Desc./Quantity
Gear ratio Primary gears 31/60
1º gear ratio 15/34 (secondary)
2º gear ratio 19/31 (secondary)
3º gear ratio 20/26 (secondary)
4º gear ratio 22/24 (secondary)
5º gear ratio 25/24 (secondary)
TUONO R_FACTORY Characteristics
CHAR - 11

Specification Desc./Quantity
6º gear ratio 26/23 (secondary)
Final drive gear ratio 16/40
Capacities
CAPACITY
Specification Desc./Quantity
Fuel (reserve included) 18 l (4.76 USgal)
Fuel reserve 4 +/- 1 l (1.06 +/- 0.26 USgal)
Engine oil oil change: 3700 cm³ (225.78 cu.in) - oil and oil filter change:
3900 cm³ (237.99 cu.in)
Oil for R fork 520.0 +/- 2.5 cm³ (31.73 +/- 1.15 cu.in) (for each stem)
Oil for Ohlins fork FG8903 fork type, oil level from the sleeve rim : 85 mm (3.35
in) - (Code stamped on inner side of calliper mounting bracket)
Coolant 2.2 l (0.58 USgal) (50% water + 50% ethylene glycol antifreeze
fluid)
Seats 2
Vehicle max. load R 192 kg ( 423.3 lb) - FACT. 196 kg (432.1 lb) (driver + pas-
senger + luggage)
Drive chain
TRANSMISSION CHAIN
Specification Desc./Quantity
Type endless (without master link) and with sealed links
Model 525
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Battery 12V - 10 Ah
Main fuses 30 A
Auxiliary fuses 5A, 15A, 20A
Generator (permanent magneto) 12V - 500W
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type box section sloping twin-spar frame in aluminium alloy.
Steering inclination angle 25°
Front stroke 101.7 mm (4.00 in) (with 120/70 tyres)
SUSPENSIONS
Specification Desc./Quantity
Front: adjustable upside-down hydraulic action telescopic fork, Ø 43
mm (1.69 in) stems
Travel R - 127 mm (4.99 in)
FACT - 120 mm (4.72 in)
Rear double banana aluminium alloy swing arm, gradual linkage
connecting rod, APS system. Hydraulic shock absorber, re-
bound adjustment and spring preloading.
Wheel travel 133 mm (5.39 in)
Characteristics TUONO R_FACTORY
CHAR - 12

Brakes
BRAKES
Specification Desc./Quantity
Front: Ø 320 mm (12.59 in) twin floating disc brake, Ø 34 mm (1.34
in) 4-plunger callipers
Rear Ø 220 mm (8.66 in) disc brake, calliper with Ø 32 mm (1.25 in)
twin plungers
Wheels and tyres
WHEEL RIMS
Specification Desc./Quantity
Type in light alloy with extractable bolt
Front: 3.50 x 17" DIE CAST for R version - FORGED for FACT. ver-
sion
Rear 6.00 x 17" DIE CAST for R version - FORGED for FACT. ver-
sion
TYRES
Specification Desc./Quantity
Type Standard equipment R Version:
PIRELLI DIABLO; METZELER RENNSPORT; MICHELIN PI-
LOT POWER; DUNLOP SPORTMAX D208RR
Standard equipment FACTORY Version:
PIRELLI DRAGON SUPERCORSA EVO
Front: 120/70 ZR 17''
Inflation pressure 2.53 bar (253.31 kPa) (36.74 PSI)
Rear 190/50 ZR 17"
Inflation pressure 2.83 bar (283.71 kPa) (41.14 PSI)
Type alternatively for R version: PIRELLI DIABLO CORSA; PIRELLI
DRAGON SUPERCORSA EVO; METZELER SPORTTEC;
METZELER RENNSPORT; MICHELIN PILOT POWER; MI-
CHELIN PILOT POWER RACE; DUNLOP SPORTMAX
QUALIFER
alternatively for FACTORY version: PIRELLI DIABLO CORSA;
PIRELLI DRAGON SUPERCORSA EVO; METZELER
SPORTTEC; METZELER RENNSPORT; MICHELIN PILOT
POWER RACE; DUNLOP SPORTMAX D 208 RR; DUNLOP
SPORTMAX QUALIFER
Front: 120/70 - ZR 17"
Rear 180/55 ZR 17" - 190/55 - ZR 17''
Supply
FUEL SYSTEM
Specification Desc./Quantity
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
SUPPLY SYSTEM
Specification Desc./Quantity
Type Electronic injection (Multipoint)
Diffuser Ø 57 mm (2.24 in)
TUONO R_FACTORY Characteristics
CHAR - 13

Tightening Torques
ENGINE TO CHASSIS RETAINER
Name Torque in Nm
Front clamp M10 50
Rear top and bottom left clamp M10 50
Rear top and bottom right clamp for adjust. bushing M20x1.5 12
Rear top and bottom right clamp for counter ring nut M20x1.5 50
Rear top and bottom right clamp M10 50
PARTS FIXED TO THE ENGINE
Name Torque in Nm
Engine oil intake flange M6 10
Engine oil outlet flange M6 10
Rear brake lever support M6 10
Rear brake lever support M8 25
Rear brake pump support M8 25
Pinion clamp M10 50 - Loctite 243
Clutch pin clamp M6 10
Pinion crankcase clamp M6 10
Retainer for pipe delivering fuel to throttle body M12X1.5 22
retainer for 72/78 kW reduction bushing M5 3 - (shear head screw ) Loctite 243
SWING ARM
Name Torque in Nm
bolt ring nut for swing arm M30x1.5 60
swing arm bolt for adjustment bushing M30x1.5 12
swing arm bolt nut M20x1.5 90
Lock bolt of calliper support M12 50 - Loctite 243
Chain tensioner screw and nut M8 manual
Retainer for rear brake pipe cable guide M5 4
Top retainer of chain crankcase M5 4
bottom retainer of crankcase chain and chain eye support M5 5
Chain guide pad retainer M5 3
Retainer for fixing upper chain eye to chain eye support M5 5
Rear stand bushing retainer M6 10
Chain eye retainer M6 10
SIDE STAND
Name Torque in Nm
Stand plate to chassis retainer M10 50
Side stand retainer bolt M10x1.25 10
Switch fixing screws M6 10 - Loctite 243
Lock nut M10x1.25 30
FRONT FORK
Name Torque in Nm
Fork stem to upper plate retainer M8 25
Fork stem to lower plate retainer M8 25
Headstock ring nut M35x1 40
Headstock counter ring nut M35x1 Manual + 90°
Upper plate fixing cover M29x1 100
(Showa) Fork hub cap nut M8 22
(Ohlins) Fork hub cap nut M6 12
STEERING SHOCK ABSORBER
Name Torque in Nm
Shock absorber to chassis retainer M6 10 - Loctite 243
Shock abs. stem to lower plate retainer M6 10
Characteristics TUONO R_FACTORY
CHAR - 14

FOOTRESTS
Name Torque in Nm
Driver footrests M8 2.5
Passenger footrests M8 2.5
REAR SHOCK ABSORBER
Name Torque in Nm
Shock absorber to chassis retainer M10 50
CONNECTING RODS
Name Torque in Nm
Single connecting rod to chassis retainer M10 50
Single connecting rod/double connecting rod retainer M10 50
Double connecting rod/swing arm retainer M10 50
Double connecting rod/shock absorber retainer M10 50
ELECTRICAL SYSTEM
Name Torque in Nm
Battery clamping bracket M5 2
Horn M8 15
Odometer sensor to rear brake calliper support retainer M6 12
Voltage regulator support retainer M6 10
Voltage regulator to support retainer M6 10
Coil support to chassis retainer M6 10
Coil to coil support retainer M6 10
Control unit retainer M6 10
Start-up relay support on saddle pillar retainer M6 10
Bracket retainer for relay holder on saddle pillar M6 3
Atmosphericpressuresensortosaddle pillarclampretainer M5 1
Cable on starter motor retainer M6 5
Retainer for start-up relay cables M6 4
Ground lead to engine retainer M6 5
SWP 3.9 Plate retainer for main cable harness on air intake 1
LIGHTS / INSTRUMENT PANEL
Name Torque in Nm
Rear arrow retainer M4 1
Front arrow retainer M6 4
Rear light to tail retainer M5 2
Front headlamp to deflector retainer M5 2
Front headlamp to front fairing retainer M5 2
SWP 5x14 Instrument panel retainer 3
FILTER HOUSING
Name Torque in Nm
SWP 5x20 Filter housing cover 3
Filter housing to throttle body retainer M6 5
SWP 3.9 Intake ducts 1
SWP 5x20 MAP sensor support retainer 2
SWP 5x20 Filter frame retainer 2
Deflector to chassis retainer M6 10
REAR WHEEL
Name Torque in Nm
Crown on crown holder retainer M10 50
Rear wheel bolt nut M25x1.5 120
FRONT WHEEL
Name Torque in Nm
Wheel bolt nut M25x1.5 80
TUONO R_FACTORY Characteristics
CHAR - 15

COOLING SYSTEM
Name Torque in Nm
Water radiator upper support to chassis retainer M6 10
Electrical fan to water radiator retainer M6 6
Water radiator to upper support retainer M6 10
Filler to water radiator retainer M6 -
Retainer for attaching water radiator side supports to engine
coupling spacers M6 10
Water radiator to side supports retainer M6 6
Oil radiator support to engine retainer M6 10
Oil radiator to oil radiator support retainer M6 10
Expansion tank to chassis retainer M6 10
Expansion tank cover retainer M28x3 6
8104097 Hose clamp retainer 4
FRONT BRAKING SYSTEM
Name Torque in Nm
Front brake right and left calliper retainer M10x1.25 50
Front brake oil reservoir to bracket retainer M6 7
Retainer for front brake fluid reservoir to clutch upper bracket
M6 10
Clutch fluid reservoir to bracket retainer M5 3
Retainer for front brake pipe cable guide to lower steering plate
M5 4
Brake disc retainer M8 30 - Loctite 243
REAR BRAKING SYSTEM
Name Torque in Nm
Rear brake calliper retainer M8 25
Rear brake lever pin M8 15 - Loctite 243
Rear brake fluid reservoir retainer M5 3
Rear brake rod lock nut M6 manual
Brake disc retainer M8 30 - Loctite 243
EXHAUST
Name Torque in Nm
Front exhaust pipe to engine retainer M6 12
Rear exhaust pipe to engine (upper screws) retainer M6 manual
Rear exhaust pipe to engine (lower screws) retainer M6 12
Lambda probe retainer M18x1.5 38
Rear manifold protection retainer M4 2.5
Silencer to support retainer M8 25
Protections to silencer retainer M4 2.5
FUEL PUMP
Name Torque in Nm
Fuel return pipe fitting M6 6 (Loctite 243)
Pump support to flange retainer M5 4
Wire cap to flange retainer M5 5
Fuel return pipe clamp M6 10 (Loctite 243)
Petrol delivery pipe on flange M12x1.5 22
Fuel level sensor on pump support SWP 2,9x12 1
Fuel pump cable harness on flange M6 10
TANK
Name Torque in Nm
Filler to tank retainer M5 5
Fuel pump flange to tank retainer M5 6
Characteristics TUONO R_FACTORY
CHAR - 16

ENGINE OIL RESERVOIR
Name Torque in Nm
Oil reservoir retainer (nuts) M6 10
Oil filter shank M20x1.5 30
Oil drainage plug M8 15
Oil level pipe retainer M10x1 20
LOWER SADDLE PILLAR CLAMP
Name Torque in Nm
Lower clamp to saddle pillar retainer M6 5
Lower clamp to chassis retainer M5 4
Rear stand bushing retainer for lower saddle pillar clamp M6 12
LICENSE PLATE HOLDER
Name Torque in Nm
Retainer fixing license plate holder to lower saddle pillar clamp
M6 3
Retroreflector to license plate holder retainer M4 1
MUDGUARDS
Name Torque in Nm
Front mudguard retainer M5 5
Rear mudguard retainer M5 5
TAIL
Name Torque in Nm
Tail to saddle pillar retainer M5 5
Tail camp to saddle pillar retainer M6 7
RIGHT / LEFT FAIRING
Name Torque in Nm
Fairings to tail retainer M5 2
Fairings to tank retainer M5 5
LUG
Name Torque in Nm
Retainerfixing lug assembly tooil radiator support and spacers
on engine M6 7
RIGHT/LEFT SIDE COVERS
Name Torque in Nm
Rear side cover retainer M6 7
Front side cover retainer (with spoiler spacers) M6 10
Retainer for right side cover to voltage regulator support M6 5
RIGHT/LEFT RADIATOR FAIRING
Name Torque in Nm
SWP 3.9 Retainer fixing radiator right-left fairing to fan pin 1
RIGHT / LEFT SPOILER
Name Torque in Nm
Rear spoiler to spacer retainer M6 7
Front spoiler to water radiator retainer M6 7
OIL RESERVOIR COVER
Name Torque in Nm
Oil reservoir retainer M5 5
TUONO R_FACTORY Characteristics
CHAR - 17

FRONT
Name Torque in Nm
Front retainer fixing headlight assembly and deflector M5 3
WINDSHIELD
Name Torque in Nm
Front fairing retainer M4 1
RADIATOR SPOILER
Name Torque in Nm
Retainer for water radiator bottom supports M5 3
FORK BOTTOM CLAMP
Name Torque in Nm
Steering lower plate retainer M6 3
Retainer fixing steering lower plate to steering shock absorber
M6 10
SADDLE COVER
Name Torque in Nm
SWP 3.9 Saddle cover base retainer 1
HANDLEBAR AND CONTROLS
Name Torque in Nm
handlebar support upper U-bolt M8 25
Retainer fixing handlebar supports to steering top plate (only
for workshop manual) M10 30 - Loctite 243
Anti-vibration weight retainer M6 10
Terminals to anti-vibration weights retainer M18x1 35
Left light switch M5x1 1.5
Right light switch M4 1.5
Front brake pump retainer M6 8
Clutch pump retainer M6 8
LOCKS
Name Torque in Nm
Key switch to steering plate retainer M8 25
Rear lock to tail retainer M22x1.5 10 - Nylon nut
CHASSIS
Name Torque in Nm
Chain bottom pad retainer M6 10
Saddle pillar retainer M10 50
PARTS FIXED TO THE ENGINE
Name Torque in Nm
Engine oil intake flange M6x20 11
Engine oil drainage plug M12x1.5 20
Pinion retainer M10x35 50
Clutch control cylinder retainer M6x45 11
Coolant drainage screws M6x25 11
Gearbox lever fixing screws 12
ENGINE CRANKCASE
Name Torque in Nm
Torx screws locking ball bearings of selector roller / crankcase
[flywheel side (MS)] M6x12 11 - Loctite 243
ball bearings of selector roller /crankcase [clutch side (KS)]
M6x20 11
Characteristics TUONO R_FACTORY
CHAR - 18

Name Torque in Nm
Torx ball bearings of propeller shaft /crankcase [clutch side
(KS)] M6x12 11 - Loctite 243
Crankcase [flywheel side (MS)] / crankcase [clutch side (KS)]
M6x45 11
Crankcase [flywheel side (MS)] / crankcase [clutch side (KS)]
M6x65 11
Crankcase [flywheel side (MS)] / crankcase [clutch side (KS)]
M6x80 11
Crankcase (magnetic screw) M12x1.5 20
Crankcase neutral sensor 4 - Loctite 574
Oil filter cover M6x20 11
Crankcase/nozzle 60 6
Bearing flange [flywheel side (MS)] M6x12 11 - Loctite 243
OIL PUMP
Name Torque in Nm
Oil pump -
Oil pump body -
Oil pump cover M6x45 11
CLUTCH
Name Torque in Nm
Main shaft [clutch side (KS)] M24x1.5 170 - Loctite 648
Clutch spring M6x30 11
Disengaging shaft M12 30
Main transmission (spring holding plate/ main transmission
gear / clutch bell) M8x25 30
Main transmission (spring holding plate/ main transmission
gear / clutch bell) M8 30 - Loctite 648
CYLINDER HEADS AND CYLINDERS
Name Torque in Nm
Camshaft support / front cylinder head M6x30 11
Front cylinder head (water hose) M18x1.5 manual - Loctite 275
Front cylinder head cover M18x1.5 manual - Loctite 243
Rear cylinder head (water hose) M18x1.5 manual - Loctite 275
Camshaft support / rear cylinder head M6x30 11
Camshaft support / rear cylinder head M6x55 11
Camshaft support / rear cylinder head M6x45 11
Discharge stud bolt M6x16/20 10 - Loctite 275
Rear cylinder head Manual - Loctite 275
Cylinder head / crankshaft (screw stud) M10x171 6 - Loctite 648
Cylinder / cylinder head (version with non-coated cylinder)
M8x45 27
Cylinder head / screw stud (version with non-coated cylinder
head) M10x4 58
Cylinder head / chain compartment M6x100 12
Rear cylinder head / bushing flange M6x35 11
Rear cylinder head / bushing flange M6x20 11
Front cylinder head / Driven gear (timing system chain) - Cam-
shaft intake M6x45 11 - Loctite 243
Front cylinder head / top chain guide M6x16 11
Rear cylinder head / Driven gear (timing system chain) - Cam-
shaft intake M6x11.5 11 - Loctite 243
Rearcylinderhead / Counterweight + Driven gear(uppercoun-
tershaft assembly) - Upper counter shaft M14x1 50 - Loctite 243
Rear cylinder head / Upper chain guide M6x35 11
Valve cover M6x23 9
Intake flange M8x25 19
Cylinder / chain tensioner M16x1.5 30
Water temperature sensor 20
Supporting bracket retainer M10; M10x40 40 - Loctite 243
TUONO R_FACTORY Characteristics
CHAR - 19

IGNITION SYSTEM AND STARTER MOTOR
Name Torque in Nm
Camshaft position sensor / front cylinder head M6x15 11
Starter motor M6x30 11
Crankshaft position sensor / flywheel cover M6 11 - Loctite 243
Flywheel cover / generator M6x35 11
Magneto flywheel / freewheel housing / flywheel ring M8x18 30 - Loctite 648
Magneto flywheel / crankshaft M16x30 130 - Loctite 648
Ignition device cover / cable holding bracket M5 7
CLUTCH AND COOLANT PUMP COVER
Name Torque in Nm
Coolant pump rotor manual
Coolant pump cover M6x25 11
Coolant pump body M6x55 11 - Loctite 243
Clutch cover M6x35 11
Clutch cover M6x50 11
Clutch cover M8x55 19
Clutch cover M8x65 19
Overhaul data
Assembly clearances
Cylinder - piston assy.
CYLINDERS
All seal surfaces must be clean and flat. Seal surface levelness:
Max. distortion allowed 0.04 mm (0.0016 in).
Make sure all threads are in proper conditions. Check cylinder sliding surface for signs of friction and
scratches. Also check the seal surfaces for damages.
CAUTION
REPLACE CYLINDER OR PISTON IF GROOVES ON THE NIKASIL LINER, CYLINDER INNER
SIDE, ARE EVIDENT.
Clean off lime scales on the cylinder cooling slots.
Measure the cylinder bore 45 mm (1.77 in) from
the upper rim (1) at three different points; the high-
est value should be considered to estimate wear
limits.
CAUTION
EITHER GROUP "A" OR "B" IS PUNCHED AT THE BOT-
TOM OF CYLINDER (2).
Characteristics TUONO R_FACTORY
CHAR - 20