Aprilia TUONO 1000 User Manual 2006

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CHECKING THE SIDE STAND

Carefully read page 79 (MAINTENANCE) and page 92 (CHECKING THE SWITCHES).

The side stand (1) has two positions:

normal or stowed (Pos. A);

extended (Pos. B).

The rider must make sure that the stand is safely and completely extended, or completely stowed, as required.

The side stand (1) must rotate around its pivot smoothly and easily.

The springs (2) provide for keeping the stand in the desired position (extended or stowed).

Perform the following checks:

uPlace the vehicle on the appropriate rear support stand, see page 99 (PLACING

THE VEHICLE ON THE REAR SUPPORT STAND) .

uThe springs (2) must not be damaged, worn,or rusted, and must fully and firmly stow the side stand when the weight of the vehicle is lifted off of it.

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uMake sure that the stand presents no slack in either position (extended or stowed).

uExtend the stand, making sure that the action of the springs ensures complete extension.

uMove the stand to stow it and release it when it has reached half its stroke to make sure that the action of the springs is sufficient to stow it completely.

uThe side stand (1) must rotate freely around its pivot. If necessary, lubricate the pivot, see page 141 (LUBRICANT CHART).

CHECKING THE FUNCTIONING OF THE SAFETY SWITCH

ON THE SIDE STAND

The side stand (1) is equipped with a safety system, operated by a safety switch (3).

This system prevents the motor from being started while the stand is extended unless the transmission is in neutral. It also kills the engine if the stand is extended while the engine is running, unless the transmission is

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in neutral.

To check the proper functioning of the safety switch (3):

uRemove the rear support stand ,

see page 99 (PLACING THE VEHICLE ON THE REAR SUPPORT STAND) .

uSit on the vehicle in the normal riding position, see page 64 (GETTING ON AND OFF THE VEHICLE).

uStow the side stand (1) carefully and completely.

WARNING

E x h a u s t g a s e s c o n t a i n c a r b o n m o n o x i d e , w h i c h i s e x t r e m e l y poisonous if inhaled.

Do not start the engine in closed or poorly-ventilatedrooms.

Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.

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uStart the engine, see page 68 (STARTING).

uRelease the throttle grip (4) (Pos. C). With the engine idling, pull in the clutch lever (5) completely.

uEngage first gear, pushing the shift lever

(6) downwards.

uExtend the side stand (1).

NOTE Extending the side stand must kill the engine and the “side stand down” warning light “” (7) must come on. If the engine continues to run:

uCheck the safety switch (3) on the side stand (1), see page 92 (CHECKING THE SWI TCHE S) . P e r for m the necessary cleaning or repairs.

uRepeat the check.

WARNING

If the engine does not stop when the side stand is extended, do not ride your vehicle. Contact your Local aprilia Dealer.

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CHECKING THE SWITCHES

C a r e f u l l y

r e a d

p a g e 7 9

(MAINTENANCE).

 

 

Check the switches after the first 600 mi (1,000 km) and thereafter every 4,650 mi (7,500 km).

The vehicle is equipped with four switches:

stoplight switch on the rear brake pedal (1);

stoplight switch on the front brake lever (2);

safety switch on the side stand (3);

clutch lever switch (4).

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uMake sure that there is no dirt or mud on the switch. The switch pin must move freely and without interference, returning automatically to its unapplied position.

uCheck the spring (5); it must not be damaged, worn or stretched.

uMake sure that the cables are connected correctly.

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INSPECTING THE FRONT

AND REAR SUSPENSIONS

CAUTION

The front fork oil change operation should be entrusted to your Local aprilia Dealer.

Carefully read page 79 (MAINTENANCE).

WARNING

Reduce the service intervals by half when the vehicle is used in rainy or dusty conditions, on rough roads or for racing.

NOTE Reduce the service intervals by half when the vehicle is used in rainy or dusty conditions, on rough roads or for racing.

Have the front fork oil changed after the first 6,250 mi (10,000 km) and then every 12,500 mi (20,000 km).

Carry out the following checks after the first 625 mi (1,000 km) and every 6,250 mi 10,000 km) thereafter:

uApply the front brake lever and push up and down on the handlebar repeatedly, pushing the fork up and down.

The fork must move smoothly and easily, there must be no trace of oil on the fork tubes.

uCheck the torque of all the fasteners on the front fork and inspect the entire front fork to make sure that it is in good condition without leaks or damage. Repeat for the rear suspension and swingarm.

CAUTION

Do not ride your vehicle if either suspension is damaged in any way, contact your Local aprilia Dealer.

FRONT SUSPENSION

After the first 18,750 mi (30,000 km) and then every 12,500 mi (20,000 km), check, clean and lubricate the fork oil seals. If necessary, have them replaced by an aprilia dealer.

The front suspension is controlled by a hydraulic fork, which is held to the steering tube by two yokes.

Each fork leg is fitted with suitable adjusters to modify suspension response. An upper adjuster screw (1) controls rebound damping, whereas a lower adjuster screw (2) controls compression damping. A top-mountedadjuster nut (3) controls spring preload.

SETTING THE FRONT FORK

CAUTION

Do not force the adjusters (1-2)beyond their limit stops in either direction, or the threads may strip. Set both fork legs t o t h e s a m e s p r i n g p r e l o a d , compression and rebound damping settings: a vehicle whose fork legs are set to different settings will be unstable. When spring preload is increased, rebound damping should be increased accordingly. Failure to do so may result in the front end jerking unexpectedly when riding.

For fork setting, see next page.

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FORK

Factory setting is designed for any riding condition, low or high speed, with reduced or full load.

However, suspension setting may be m o d i f i e d t o s u i t s p e c i f i c n e e d s i n accordance with vehicle use.

WARNING

For a correct setting of adjusters (1-2-3),first set the fork to the stiffest position (turn the adjuster fully clockwise) then set desired position (clicks and/or turns).

WARNING

Racing settings may only be used during official competitions or sports events authorized by the competent authorities and taking place in closed circuits or, anyway, away from public roads.

It is strictly prohibited to carry out adjustments for the use of the vehicle on racetracks and then ride it on roads or highways.

FRONT SUSPENSION

Standard setting

Hydraulic adjustment with extended shock

Tighten fully (*) and then slacken (**)

absorber, screw (1)

by 1.5 turns

 

 

Hydraulic compression damping, screw (2)

Tighten fully (**) and then slacken (*)

 

1 turn

 

 

Spring preload, nut (3)

Tighten fully (*) and then slacken (**)

 

5 notches are in view

 

 

Fork height (A) (***) over top yoke (not

1 notch is in view

including top cap)

 

 

 

(*) = clockwise

(**) = counterclockwise

(***) = Have this adjustment carried out exclusively by an Local aprilia Dealer

For racing we recommend to fit the Öhlins multi-adjustablefront fork unit. For purchase contact an Local aprilia Dealer.

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STEERING DAMPER

The standard model is equipped with a steering damper.

REAR SUSPENSION

The rear suspension consists of a springshock absorber unit, fixed to the frame by means of a uniball and to the swingarm by means of lever systems.

The rear suspension is equipped with the following adjusters: a screw (1) for rebound, a ring nut (2) for adjusting the spring preload and a locking ring nut (3).

A DJ US T I N G T H E R E A R S H O C K ABSORBER

NOTE R e d u c e t h e m a i n t e n a n c e intervals by half if you are riding in rainy or dusty conditions, on rough road surfaces o r w h e n t h e v e h i c l e i s u s e d i n competitions.

Check and if necessary adjust the rear shock absorber every 12,500 mi (20,000 km).

The factory setting is designed for racing.

However, the rear suspension setting may be modified to suit specific needs in accordance with vehicle usage.

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CAUTION

Before adjusting, first set the rear shock absorber to the stiffest setting [turn the adjusters (1) fully clockwise].

Do not force the adjusters (1) beyond their limit stops in either direction, or the threads may strip.

uLoosen the locking ring nut (3) with an appropriate wrench.

uAdjust spring preload (A) with the adjusting ring nut (2) (see table).

uWhen finished, tighten the ring nut (3).

uWork the screw (1) to set shock absorber rebound damping (see table).

CAUTION

S e t s p r i ng p r e l o a d a n d r e b ou n d damping according to vehicle usage. When you increase spring preload, you will have to increase rebound damping accordingly to avoid unexpected jerking when riding.

If necessary, contact your Local aprilia Dealer.

WARNING

 

Racing settings may only be used

 

during official competitions or sports

 

events authorized by the competent

 

authorities and taking place in closed

 

circuits or, anyway, away from public

 

roads.

 

 

It is strictly prohibited to carry out

 

adjustments for the use of the vehicle

 

on racetracks and then ride it on roads

 

or highways.

 

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F R O N T

Standard setting

2

 

SUSPENSION

 

 

S p r i n g l e n g t h

147 mm

A

(preloaded) (A)

 

R e b o u n d

tighten fully (*) and

 

a d j u s t m e n t ,

then slacken (**) by 25

 

screw (1)

click positions

 

For racing we recommend to fit the Ö h l i n s m u l t i - a d j u s t a b l e r e a r suspension unit . For purchase contact an Local aprilia Dealer.

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CHECKING THE BRAKE PAD WEAR

Carefully read page 50 (BRAKES), and page 79 (MAINTENANCE).

NOTE The following instructions apply to both braking systems.

NOTE Your vehicle is equipped with disc brakes and two separate brake systems. The front brake system is equipped with two discs, one on the right and one on the left side of the front wheel. The rear brake system is equipped with a single disc on the right side of the wheel. The following information may refer to a single braking system, but is applicable to both braking systems.

CAUTION

Reduce the service intervals by half when the vehicle is used in rainy or dusty conditions, on rough roads or forracing.

Check brake pad wear after the first 600 mi (1,000 km), before every trip and thereafter every 1,250 mi (2,000 km).

The amount of wear that the brake pads experience depends on how the vehicle is used, how aggressively it is driven, and the condition of the roads upon which it is operated. Wear will be faster than normal when the vehicle is driven aggressively, or on dusty or wet roads.

WARNING

Check the wear of the brake pads before every trip.

CHECKING WEAR OF THE BRAKE PADS

Place the vehicle on the stand, see page 77 (PLACING THE VEHICLE ON THE STAND).

NOTE The front brake calipers (left and right) are equipped with four pads for each caliper.

The rear brake caliper is equipped with two pads.

Perform a visual check of the friction material thickness. Use a flashlight. See the arrows (1) and (2) above.

If the friction material on one pad, front

(3) or rear (4), is worn to 0.06 in (1.5 mm) or less:

for the front brake calipers (left and right), have all the pads of both front brake calipers replaced by your Local aprilia Dealer.

for the rear brake caliper, have both pads of the rear brake caliper replaced by your Local aprilia Dealer.

WARNING

Excessive wear of the friction material on the brake pads will cause contact of the metal pad support with the disc. This will make a characteristic metallic noise, and sparks. By this time, you have already destroyed the disc, which must be replaced.

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D o n o t r i d e y o u r v e h i c l e i n t h i s condition, braking efficiency and safety are seriously compromised. This could cause a crash and result in serious injury or death.

WARNING

Have the pads and the discs replaced by your Local aprilia Dealer.

CHECKING THE STEERING

The operations necessary for this check require specific skills and therefore should be carried out by your Local aprilia Dealer.

CHECKING THE SWINGARM PIVOT

The operations necessary for this check require specific skills and therefore should be carried out by your Local aprilia Dealer.

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ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND

Place the vehicle on the stand, see page 77 (PLACING THE VEHICLE ON THE STAND).

Place the pin (1) on the appropriate seat on the swingarm.

Insert and tighten the screw (2) in the appropriate threaded hole (3) in the swingarm.

PLACING THE VEHICLE ON THE REAR SUPPORT STAND

Assemble the pins for the rear support stand , see above (ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND).

NOTE Have someone help you keep the vehicle vertical with the two wheels on the ground.

Slacken the knob (5).

Shift the fork-shapedsupport (4) so that its width matches the distance between the two pins (1) fitted to the swingarm.

Tighten the knob (5).

Slide both fork-shapedseats (4) of the stand (6) underneath the pins (1) fitted to the vehicle simultaneously.

Place one foot on the rear end of the stand (6).

Push the stand (6) downwards until it reaches the end of its stroke (see figure).

WARNING

Make sure that the vehicle is stable.

If it falls over, it may cause damage to bystanders and other property, as well as being damaged itself.

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PLACING THE VEHICLE ON THE FRONT SUPPORT STAND

Place the vehicle on the appropriate rear s u pp or t s t a nd , s e e p ag e 9 9 (PLACING THE VEHICLE ON THE REAR SUPPORT STAND) .

Lift the front part of the stand (1) and insert each of its ends (2) into the holes

(3) in the bottom of the front fork.

Rest one foot on the front part of the stand (1).

Push the stand (1) downwards until it reaches the end of its stroke (see figure).

WARNING

Make sure that the vehicle is stable.

If it falls over, it may cause damage to bystanders and other property, as well as being damaged itself.

FRONT WHEEL

WARNING

The disassembly and reassembly of the front wheel can be difficult for those unfamiliar with vehicle maintenance. You may wish to have your Local aprilia D e a l e r c a r r y o u t t h e s e operations.

If you wish to perform these operations y o u r s e l f , c a r e f u l ly r e a d p a ge 7 9 (MAINTENANCE).

While disassembling and reassembling the wheel, pay extra care not to damage the brake lines, discs or pads.

Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature.

Failure to observe this warning can lead to serious burns.

Riding with damaged rims in dangerous for the rider, the vehicle and other people. Check the conditions of the rim and have it replaced if it is damaged.

WARNING

Have the rim replaced by your Local aprilia Dealer. You must use the appropriate front and rear support stands

(1) (2) to remove the front wheel.

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DISASSEMBLY

Remove the front brake calipers, see page 114 (REMOVING THE FRONT BRAKE CALIPERS) .

Place a support (1) under the tire to hold the wheel in place once released.

CAUTION

Never touch the front brake lever after removing the brake calipers from the discs. If you do, the caliper pistons may be pushed out of their seats, and brake fluid will be spilled.

Should you accidentally do this, take your vehicle to your Local aprilia Dealer who will know how to repair this damage.

Place a support (1) under the front tire, so as to keep the wheel in its position after loosening it.

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