Aprilia TUONO 1000 User Manual 2006

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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.

Have a helper steady the handlebar in the straight ahead position.

Wheel nut (2) tightening torque setting: 57.86 ftlb (80 Nm).

Remove the wheel nut (2) and washer

(3).

Wheel shaft clamp screws tightening torque setting: 15.91 ftlb (22 Nm).

Loosen the two axle clamp screws (4) (right side), using the appropriate Allen wrench.

Loosen the two axle clamp screws (5) (left side), using the appropriate Allen wrench.

NOTE Observe the arrangement of the right spacer ring (6), in order to be able to reassemble it correctly.

NOTE To facilitate the extraction of the axle (7), slightly lift the wheel.

Push the axle (7) partly out of the front fork by tapping the threaded end with a rubber hammer or wooden drift.

Support the front wheel and remove the axle (7) manually by pulling it from the left side of the vehicle.

Remove the wheel by pulling it forward.

NOTE The right spacer ring (6) remains located in its seat on the wheel; but if it has come out, replace it.

REASSEMBLY

Apply a thin film of lubricating grease, see page 141 (LUBRICANT CHART), to the front axle (7).

NOTE Perform the following operation only if the right spacer ring (6) has come out of its seat on the wheel:

CAUTION

The right spacer ring (6) has shoulders of two different diameters, pay extra care to fit the ring (6) correctly.

Fit the right spacer ring (6) in its seat on the wheel (right side) with the larger diameter facing the outside of the vehicle (see figure).

CAUTION

The arrow on the wheel side indicates t h e r o t a t i o n d i r e c t i o n . U p o n reassembly, make sure that the wheel is positioned correctly: the arrow must be visible on the left side of the vehicle.

Place the wheel between the fork tubes on the support (1).

WARNING

The front wheel is heavy and can easily crush your fingers should you get them between any part of the wheel and the front fork. Do not attempt to line up the wheel and the axle clamps with your fingers. Failure to observe this warning can lead to serious personal injury.

Move the wheel around until the axle hole and the axle clamps are aligned. From the left side of the vehicle, insert the axle (7) and push in completely.

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NOTE Make sure that the axle (7) is completely inserted.

Fit the washer (3) and tighten the wheel nut (2) finger tight.

NOTE For temporary alignment of the front wheel, it is not necessary to tighten the two axle clamp screws (5) (left side) to the specified torque value.

Tighten the two axle clamp screws (5) (left side) just enough to prevent the axle

(7) from rotating.

Tighten the wheel nut (2) to its appropriate tightening torque setting.

Wheel nut (2) tightening torque setting: 57.86 ftlb (80 Nm).

Tighten the two axle clamp screws (4) (right side), using the appropriate Allen wrench.

Wheel shaft clamp screws tightening torque setting: 15.91 ftlb (22 Nm).

Loosen the two axle clamp screws (5) (left side), using the appropriate Allen wrench. Remove the support (1) from under the front tire.

Replace the left and right front brake caliper, see page 114 (REMOVING THE FRONT BRAKE CALIPERS).

Apply the front brake lever, and then push down on the handlebars, compressing the fork springs several times. This will align the fork tubes.

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

Tighten the two axle clamp screws (5) (left side), using the appropriate Allen wrench.

Wheel shaft clamp screws tightening torque setting (5): 15.91 ftlb (22 Nm).

Make sure that the following components are neither dirty nor oily:

– tire; wheel; brake discs.

WARNING

After servicing the brakes, always check that they operate correctly. If the stroke of the lever or pedal is excessive, or if you detect that the effectiveness of the brakes is reduced in any way, have your vehicle serviced by your Local aprilia Dealer. It may be necessary to have your dealer bleed the system, or there may be some other problem with the brake system.

Never ride your vehicle in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your vehicle. Then, try your vehicle in a parking lot or other safe area with little traffic to make sure that the brakes are working properly. Failure to observe this warning can lead to a serious accident, which can result in serious injury or death. Have the

tightening torque settings, centering and balancing of the wheel checked by your Local aprilia Dealer.

These are critical safety operations, and failure to observe this warning could lead to an upset, which can result in serious injury or death.

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REAR WHEEL

WARNING

The disassembly and reassembly of the rear wheel can be difficult for those unfamiliar with vehicle maintenance. You may wish to have your Local aprilia Dealer carry out these operations. If you wish to perform these operations yourself, carefully read page 79 (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.

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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.

NOTE You must use the appropriate rear support stand (1) to remove the rear wheel.

DISASSEMBLY

Place the vehicle on the appropriate rear

support stand

 

(1), see page 99

(PLACING THE VEHICLE ON THE REAR SUPPORT STAND) .

Place a support (2) under the tire, so as to keep the wheel in its position after loosening it.

WARNING

Make sure that the vehicle is stable.

If it falls over, it may cause injury to bystanders and other property, as well as become damaged.

Wheel nut (3) tightening torque setting: 86.80 ftlb (120 Nm).

Remove the wheel nut (3) and the washer

(4).

NOTE To facilitate the extraction of the axle (5), slightly lift the wheel.

Remove the axle (5) from the left side of the vehicle.

NOTE Observe the arrangement of the right (6) and left (7) chain tensioners in order to be able to reassemble them correctly.

Remove the right (6) and left (7) chain tensioners.

WARNING

Keep your fingers well away from the chain and sprocket. You could easily lose a finger if it is caught between these two parts.

Use heavy work gloves while installing the rear wheel. Never attempt to line the rear wheel up using your fingers. Failure to observe this warning can result in serious personal injury.

Remove the drive chain (8) from the rear sprocket (9) and lay it down outside of the rear sprocket.

NOTE Place the drive chain (8) outside of the rear sprocket (9).

Move the wheel forward and pull the drive chain (8) away from the rear sprocket (9).

CAUTION

Never touch the rear brake pedal after removing the rear wheel. 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.

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Pull the wheel backwards, removing it from the swingarm from behind, carefully removing the disc from the brake caliper.

NOTE The left spacer ring (10) and the right spacer ring (11) remain in their seats on the wheel; collect them if they have come out.

NOTE The torque plate (12) of the brake caliper (13) remains installed on the right side of the rear fork.

Proceed with care. If the final drive unit (14) is installed on the flexible coupling holder (15), do not overturn or rotate the rear wheel in horizontal position on the rear sprocket side (A), since the final drive unit would come off and fall, and this could damage the rear sprocket (9).

NOTE If the wheel is in the normal running position (vertical) or in horizontal position with the rear sprocket facing upwards and in both cases secured against overturning, it is not necessary to remove the final drive unit.

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NOTE Do not loosen the five nuts (16). The complete final drive unit must be withdrawn from the flexible coupling holder.

Working (B) with both hands on the outer diameter of the sprocket (9), withdraw the final drive unit parallel to the wheel axis.

REASSEMBLY

If the final drive unit has been removed (14):

NOTE Introduce the final drive unit, parallel to the wheel axis, inserting the flexible couplings in the corresponding seats on the flexible coupling holder (15).

Working (C) with both hands on the outer diameter of the sprocket (9), insert the final drive unit in the flexible coupling holder (15).

CAUTION

While reassembling the rear wheel, be careful not to damage the brake line, the disc and the pads.

NOTE Perform the follow operation only if the left spacer ring (10) and/or the right spacer ring (11) have come out of their seats on the wheel:

Fit the left (10) and right (11) spacer rings in their seats on the wheel with the larger diameter facing the outside of the vehicle (see figure).

CAUTION

Before proceeding with reassembly, make sure that the torque plate (12) of the brake caliper (13) is positioned correctly; the plate slot must be inserted in the appropriate stop pin (17) in the inner part of the right side of the swingarm. Insert the disc in the brake caliper carefully.

Place the wheel centrally on the swingarm, on the support (2).

WARNING

Keep your fingers well away from the chain and sprocket. You could easily lose a finger if it is caught between these two parts. Use heavy work gloves while installing the rear wheel. Never attempt to line the rear wheel up using your fingers. Failure to observe this warning can result in serious personal injury.

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Move the wheel as far forward as possible, to fit the drive chain (8) on the rear sprocket (9).

Fit the right (6) and left (7) chain t i g h t e n e r s i n t h e i r s e a t s o n t h e swingarm.

Apply a thin film of lubricating grease, see page 141 (LUBRICANT CHART), to the rear axle (5).

Pull the rear wheel backwards until the bearing holes are lined up with the holes in the swingarm.

Rotate the torque plate (12), complete with brake caliper (13), with the stop pin (17) in proper position until it is appropriately aligned with the holes in the swingarm.

NOTE To facilitate the insertion of the axle (5), slightly lift the wheel.

Fit the axle (5) completely through the wheel from the left side.

NOTE Make sure that the axle (5) is pushed all the way home with the head in the appropriate seat on the left chain tightener.

Fit the washer (4) and tighten the wheel nut (3) finger tight.

Remove the support (2) from under the rear tire.

Check the chain tension, see page 105 (DRIVE CHAIN).

Tighten the wheel nut (3).

Wheel nut (3) tightening torque setting: 86.80 ftlb (120 Nm).

Make sure that the following components are neither dirty nor oily:

tire;

wheel;

brake disc.

WARNING

After servicing the brakes, always check that they operate correctly. If the stroke of the lever or pedal is excessive, or if you detect that the effectiveness of the brakes is reduced in any way, have your vehicle serviced by your Local aprilia Dealer. It may be necessary to have your dealer bleed the system, or there may be some other problem with the brake system.

Never ride your vehicle in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your vehicle. Then, try your vehicle in a parking lot or other safe area with little traffic to make sure that the brakes are working properly. Failure to observe this warning can lead to a serious accident, which can result in serious injury or death.

Have the tightening torque settings, centering and balancing of the wheel checked by your Local aprilia Dealer. These are critical safety operations, and failure to observe this warning could lead to an upset, which can result in serious injury or death.

2525mmmm

0,980,98inchinch

DRIVE CHAIN

 

 

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(MAINTENANCE).

 

 

Every 300 mi (500 km) check the condition, wear, play (tension) and lubrication of the drive chain.

The vehicle is equipped with an endless chain. There is no master link.

WARNING

An excessively loose chain may cause noise or make the chain rattle, with consequent wear of the shoe and of the chain guide plate. Do not ride your vehicle with an improperly adjusted chain, see page 106 (ADJUSTMENT). To inspect the condition of the chain, grasp the chain where it goes around the sprocket and try to pull it away from the sprocket. If you can move it more than one-eighthof an inch away from the sprocket, the chainis worn out and the chain and both front and rear sprockets must be replaced. See your Local aprilia Dealer.

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CAUTION

L a c k o f m a i n t e n a n c e c a n c a u s e premature wear of the chain and damage to the sprockets.

Service the chain more often if your vehicle is used on dusty or muddy roads.

WARNING

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.

WARNING

Keep your fingers well clear of the chain and sprocket, especially if you are turning the rear wheel while working on the vehicle. You can easily be seriously injured if a finger is caught between the chain and sprocket. Use work-glovesto carrying out these operations.

CHECKING THE PLAY

To check the play:

Stop the engine.

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

Shift to neutral.

Check the chain play. It should be 0.98 in (25 mm) atmid-bottomspan as shown above.

Move the vehicle forward or backward, or support the rear wheel in the air and turn the wheel to several positions, to check the chain slack at several locations. If the slack is markedly different with the wheel in different positions, the chain and sprockets must be replaced.

WARNING

Never operate your vehicle with a damaged chain. This could cause wheel seizure which could lead to an upset and result in serious injury or death. Lubricate the chain frequently to minimize the possibility of this kind of damage, see page 107 (CLEANING AND LUBRICATION).

If the play is the same at several locations, but is more or less than 0.98 in (25 mm), adjust it, see below (ADJUSTMENT).

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ADJUSTMENT

NOTE T o a d j u s t t h e c h a i n i t i s necessary to use the appropriate rear support stand.

To adjust the chain tension:

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) .

Wheel nut (1) tightening torque setting: 86.80 ftlb (120 Nm).

Loosen the nut (1) several turns.

NOTE In order to make wheel centering in the swingarm easier, there are reference marks (2) and (3) on the swingarm. See illustration above.

Loosen the two lock nuts (4).

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Adjust the tension adjusters (5) to obtain the appropriate chain play, making sure that the edge of tension adjuster is in the same position with regard to the reference marks (2) and (3) on each side of your vehicle.

Tighten the two lock nuts (4). Tighten the nut (1).

Wheel nut (1) tightening torque setting: 86.80 ftlb (120 Nm).

Check the chain play again, see page 106 (CHECKING THE PLAY).

CHECKING THE WEAR OF THE CHAIN AND SPROCKETS

In addition to the check, see page 106 (CHECKING THE PLAY), every 6,250 mi (10,000 km) inspect the chain and sprockets to make sure that there are no:

damaged rollers;

loose pins;

dry, rusty, crushed or seized links;

excessive wear;

missing O-rings;

sprocket or teeth excessively worn or damaged.

You may check the wear of the chain and sprocket by grasping the chain where it touches the rear sprocket, and pulling it away from the sprocket as far as you can. If you are able to pull the chain far enough away from the sprocket so that you can see light between the side plates of the chain and the sprocket teeth, the chain and sprocket are worn out and should be replaced.

NOTE Always replace both sprockets a n d t h e c h a i n w h e n a n y o f t h e se components are replaced.

CAUTION

If chain rollers are damaged, the pins and/or the O-ringsare loose or missing, both sprockets as well as the chain must be replaced.

CAUTION

L u b r i c a t e t h e c h a i n f r e q u e n t l y , especially if it is rusty or dry to the touch. If, after lubricating the chain, it still has links which cannot be turned easily, the chain must be replaced.

Check the wear of U-shapedchain guide

(6).

Finally, check the wear of the swingarm protection shoe (7).

CLEANING AND LUBRICATION

CAUTION

The drive chain is provided with O-ringsbetween the link rollers and side plates, in order to retain the lubrication and to exclude dirt and grit.

Carry out chain adjustment, lubrication, cleaning and replacement with great care. Remember to keep your fingers clear of the chain and sprocket.

Never wash the chain with jets of water, steam, high-pressurewater and highly flammable solvents.

Wash the chain with a nonflammable solvent. If your chain rusts quickly, lubricate it more often.

Lubricate the chain every 625 mi (1,000 km) or whenever it appears dry.

After washing the chain and letting it dry, lubricate it exclusively with spray grease for chains provided with sealing rings, see page 141 (LUBRICANT CHART).

CAUTION

Make sure that the chain lubricant you use is appropriate for O-ringchains. There are some lubricants available which contain substances which will destroy theO-ringsin your chain. If you have any questions, contact your Local aprilia Dealer.

NOTE D o n o t u se t h e v e h i c l e immediately after lubricating the chain, give the lubricant a chance to dry, otherwise the chain will spray the lubricant all over you and your vehicle.

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REMOVING THE RIDER SEAT

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

Turn the ignition switch (1) to the “ “ (OFF) position.

Partially lift the rear side edge of the rider seat.

Loosen and remove the screw (2) and the bushing (3).

Screw (2) tightening torque setting: 8.68 ftlb (12 Nm).

Lift and remove the seat(4).

NOTE Upon reassembly, insert the front tab of the seat in the appropriate housing.

CAUTION

Do not leave your vehicle unattended without making sure that the seat (4) is properly positioned and locked. Should you forget and ride away with the seat loose, you could be injured.

LIFTING THE FUEL TANK

Carefully read page 47 (FUEL) and page 79 (MAINTENANCE).

WARNING

Risk of fire.

Wait until the engine and the exhaust silencer have completely cooled down. Fuel vapors are hazardous for your health. Make sure that the room in which you are working is properly ventilated.

Do not inhale fuel vapors.

Do not smoke and do not use open flames.

DISPOSE OF UNWANTED FUEL PROPERLY.

CAUTION

Never drain the fuel tank, either partially or completely. This may cause damage to the inner components of the fuel tank,or to other parts of the fuel system.

Always make sure that the fuel filler cap is correctly closed.

Remove the rider seat, see page 108 (REMOVING THE RIDER SEAT). Remove the side fairings, see page 109 (REMOVING THE SIDE FAIRINGS). Loosen and remove the two retaining screws (4) at the front end of the fuel tank (5).

Release the fuel tank support rod (8) from its anchor points (6-7).

NOTE Therubber-coatedend of the rod

(8) must be introduced in the central hole of the steering shaft.

Lift the front end of the fuel tank (5) and insert the rod (8) as shown.

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REMOVING THE SIDE FAIRINGS

C a r e f u l l y

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(MAINTENANCE).

 

 

WARNING

Wait until the engine and the exhaust silencer have completely cooled down.

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

CAUTION

Handle plastic and painted components w i t h c a r e t o a v o i d s c r a p i n g o r damaging.

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Loosen and remove the two retaining screws (1) and collect the washers. Remove the fairing (2).

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Loosen and remove the retaining pin (3). Loosen and remove the retaining screw

(4) and the washer.

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Release the quick-couplingto release the hose (5).

Remove the fairing (6).

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Loosen and remove the retaining screw

(7).

Remove the fairing (8).

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Loosen and remove the two retaining screws (9) and the washers.

Remove the fairing (10).

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