Aprilia TUONO 1000 User Manual 2006

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CAUTION

Do not try to adjust the spark plug gap in any way.

The gap must be 0.024 – 0.028 in (0.6 – 0.7 mm), otherwise it is necessary to replace the spark plug.

Make sure the gasket (12) is in good condition.

TO FIT THE SPARK PLUG

With the gasket (12) in place, screw the spark plug into the head finger tight. Tighten the spark plug with the special spark plug wrench, approximately one-halfturn after it first snugly contacts the cylinder head.

Spark plug tightening torque setting: 14.47 ftlb (20 Nm).

CAUTION

The spark plug must be properly tightened, otherwise the engine may overheat and be seriously damaged.

CAUTION

Do not mix up the spark plug caps (1) position.

Fit the spark plug cap (1) properly, so that it does not come off due to the vibrations of the engine.

NOTE Repeat the operations described to remove, check and clean the other (second) spark plug of the same cylinder and the other two spark plugs of the second cylinder.

Replace the fuel tank, see page 108 (LIFTING THE FUEL TANK).

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CHANGING FUSES

 

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WARNING

Risk of fire.

Keep fuel and other flammable substances away from the electrical components.

CAUTION

Do not repair faulty fuses. Use only recommended fuses.

Using fuses of an improper capacity can cause damage to the electrical system or an electrical fire, which could result in total destruction of your vehicle as well as injury to you.

NOTE If a fuse blows frequently,there probably is a short circuit or an overload in the electrical system. If this occurs, take the vehicle to yourLocal aprilia Dealer.

If an electric component does not work or works irregularly, or if the vehicle fails to start, it is necessary to check the fuses.

Your vehicle is equipped with two group of fuses:

the 15A auxiliary fuse group (1) placed on the right side of the fairing, see page 122 (ARRANGEMENT OF 15A AUXILIARY FUSES);

the 30A main fuse group (2) placed under the rider seat, see page 122

(ARRANGEMENT OF 30A MAIN FUSES). NOTE Check the fuses in the following order:

first the fuses of the 15A auxiliary fuse group (1);

second the fuses of the 30A main fuse group (2).

To check the fuses of the auxiliary fuse group (1):

Set the ignition switch to “” to avoid any accidental short circuit.

use and maintenance TUONO 1000 USA 121

G

H

I

2

 

 

 

 

 

 

 

 

A

F

E

D

C

B

 

Remove the rider seat, see page 108 (REMOVING THE RIDER SEAT)

Open the cover of the auxiliary fuse box

(1).

Extract and check the fuses one by one - a divided link bar (2) means that the fuse is blown.

Before replacing a fuse, try to find out the cause of the trouble, if possible. Replace the damaged fuse with a new one having the same amperage.

NOTE When you use one of the spare fuses, remember to add a new fuse of equal rating to the fuse box.

Remove the rider seat, see page 108 (REMOVING THE RIDER SEAT). Repeat the process for the main fuses.

NOTE When the 30 - A fuses are removed, the digital clock and red line setting will be reset to zero.

S e e p a g e 3 4 ( M U L T I F U N C T I O N COMPUTER) for instructions on how to set the clock and red line.

ARRANGEMENT OF 5A AUXILIARY FUSES

A)From ignition key to:

light relay, brake light, horn, parking lights.

B)From ignition key to:

direction indicators, dashboard.

C)From battery to:

key positive brought to ECU.

ARRANGEMENT OF 15A AUXILIARY FUSES

D)From battery to:

speed sensor, fuel pump, relay, starter, lambda sensor.

E)From battery to:

cooling fan relay, coils, fuel injectors, air intake flaps, camshaft position sensor.

ARRANGEMENT OF 20A AUXILIARY FUSES

F)From ignition switch to: high-beamlights,low-beamlights.

NOTE There are three spare fuses (G).

ARRANGEMENT OF 30A MAIN FUSES

H)Battery charging and vehicle loads (red and red/white wires).

I)Injection loads (red and red/white wires).

NOTE There is one spare fuse (L).

CAUTION

Extract the fuses one by one, so as to avoid replacing them incorrectly during reassembly.

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NOTE If you remove one of the 30A fuses, this will reset the digital clock and the red line on zero. To reset these functions, see page 34 (MULTIFUNCTION COMPUTER).

Remove the fuses one by one and inspect the filament (9). If it is open, the fuse must be replaced.

Replace the blown fuse with the appropriate spare fuse or with a new fuse having the same amperage rating.

WARNING

If you replace the fuse and it blows again immediately, there is a serious problem with the electrical system of your vehicle. Do not attempt to continue using your vehicle. Take it to your Local aprilia Dealer for repair and service.

NOTE If you use the spare fuse, replaceit as soon as convenient.

 

 

 

BATTERY

 

 

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Your vehicle is equipped with a sealed maintenance-freebattery. Except for the tightness of the terminals, and required recharging, this battery does not require any other maintenance.

Check the tightness of the terminals after the first 600 mi (1,000 km) and thereafter every 4,650 mi (7,500 km) or 12 months.

WARNING

Batteries, when charged, give off h y d r o g e n g a s , w h i c h i s h i g h l y explosive. Therefore, do not smoke while working on or around the battery, and keep open flames or sparks away from the battery. Keep gasoline and other flammable substances well away from the battery, since a battery spark could easily ignite them and cause a devastating fire.

Since the battery gives off explosive hydrogen gas, especially when it is being charged, when you are charging a battery, make sure that the room is properly ventilated. Do not inhale the gases released during charging. Do not permit any open flames, sparks or cigarettes or any other source of heat anywhere near the battery while it is charging.

CAUTION

Never switch the battery cables . Observe the proper polarity of the battery. Incorrectly connections the battery to your vehicle will irreparably destroy the electrical system of your vehicle.

Connect and disconnect the battery only with the ignition switch (1) in the “” (OFF) position.

First connect the positive cable red (+), then the negative (–).

Disconnect the negative cable (–)first, then the positive red (+).

If your battery needs to be charged, use a constant voltage, or “taper” charger, with a current rating no greater than 1/10th the capacity of the battery (i.e., for a 50 amp hour battery, the maximum charging current should be 5 amps). Use of a more powerful charger cannot only damage the battery irreparably, but could cause it to overheat and explode.

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BATTERY STORAGE

CAUTION

If this vehicle is not used for more than twenty days, remove the 30A fuses, see page 121 (CHANGING FUSES). This will prevent the discharge of the battery c a u s e d by t h e s l i g h t c u r r e n t consumption of the multifunction computer.

NOTE The removal of the 30A fuses will reset the digital clock and the red line setting to zero. To reset these functions, see page 34 (MULTIFUNCTION COMPUTER).

Carefully read page 123 (BATTERY).

If your vehicle is not used for more than a couple of weeks, it will be necessary to “trickle charge” the battery, to prevent b a t t e r y d a m a g e , s e e p a g e 1 2 5 (RECHARGING THE BATTERY).

Remove the battery, see page 125 (REMOVING THE BATTERY), and put it in a cool, dry place.

The best way to prevent battery deterioration is to constantly leave a “trickle” charger with a capacity of about 1/10th amp attached. These chargers are inexpensive and available from your Local aprilia Dealer, and will make sure that your battery always remains in tip top condition.

If this cannot be done, charge the battery for about 30 minutes using a battery charger with a current capacity no greater than 1/10th the capacity of the battery, see page 125 (RECHARGING THE BATTERY).

It is important to check the charge periodically (about once a month), during the winter or when the vehicle is not used, in order to prevent the deterioration of the battery.

Recharge it completely with a normal charge, see page 125 (RECHARGING THE BATTERY).

While we recommend removing the battery from the vehicle, if you must leave it in your vehicle, disconnect both battery cables.

CHECKING AND CLEANING THE TERMINALS

Carefully read page 123 (BATTERY).

Make sure that the ignition switch is in the “ ” (OFF) position.

Remove the rider seat, see page 108 (REMOVING THE RIDER SEAT). Remove the red rubber boot (1).

Make sure that the cable terminals (2) and the battery terminals (3) are:

in good condition (and not corroded or covered with deposits);

covered with neutral grease or Vaseline. If it is necessary to clean the battery terminals and the cable terminals:

Remove the battery, see page 125 (REMOVING THE BATTERY).

Brush the cable terminals (2) and the battery terminals (3) with a wire brush to eliminate any sign of corrosion.

Install the battery, see page 126 (INSTALLING THE BATTERY).

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REMOVING THE BATTERY

CAUTION

When the battery is removed, the digital clock and red line setting will be reset to zero. See page 34 (MULTIFUNCTION COMPUTER) for instructions on how to set clock and red line.

Read page 96 (BATTERY) carefully.

Make sure the ignition switch is in the "" position.

Remove the rider seat, see page 108 (REMOVING THE RIDER SEAT). Loosen and remove the negative (-)terminal screw (1).

Slide the negative lead (2) aside. Lift the red protective cap (3).

Loosen and remove the positive (+) terminal screw (4).

Slide the positive lead (5) aside. Loosen and remove the two screws (6). Remove the battery retaining bracket

(7).

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8

Grasp the battery (8) firmly and lift it out of its mount.

CAUTION

Once it has been removed, store the battery in a safe place and keep it away from children. Even a completely sealed, maintenance-freebattery can be an injury hazard.

Place the battery on a level surface, in a cool, dry place.

Refit the rider seat, see page 108 (REMOVING THE RIDER SEAT).

NOTE To reinstall the battery, see page 126 (INSTALLING THE BATTERY).

CHECKING

THE ELECTROLYTE LEVEL

Carefully read page 123 (BATTERY).

Your vehicle is equipped with a sealed maintenance-freebattery that does not require checking of the battery level.

RECHARGING THE BATTERY

Carefully read page 123 (BATTERY).

WARNING

This battery is completely sealed. Do not attempt to remove the caps.

There is never any need to add water to this battery. Attempting to remove the caps will destroy the battery and could lead to injury through the spillage of caustic electrolyte. Recharge the battery according to the table below.

Remove the battery, see page 125 (REMOVING THE BATTERY).

WARNING

The battery gives off noxious and explosive gases; keep it away from flames, sparks, cigarettes and any other source of heat.

During recharging or use, make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging.

Connect the battery charger to the battery.

Set the charger for the desired type of recharge (see table).

Charge the battery using a battery charger with a current capacity of no greater than 1/10th the capacity of the battery, see page 137 (TECHNICAL DATA).

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Charge at voltage, amperage and time stated below.

Recharge

Voltage

Tension

Time

type

(V)

(A)

(hours)

 

 

 

 

Normal

12

1.0

8 – 10

 

 

 

 

Fast

12

1.0

0,5

 

 

 

 

Switch on the battery charger.

WARNING

Wait for 5 or 10 minutes after you have finished charging the battery before reinstalling it, the battery continues to produce gas for a short period of time after the charger is removed.

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INSTALLING THE BATTERY

Make sure the ignition switch is in the "" position.

Remove the rider seat, see page 108 (REMOVING THE RIDER SEAT).

NOTE Place the battery (1) with the terminals pointing to the rear of the vehicle.

Refit the battery (1) into its mount. Refit the battery retaining bracket (2).

CAUTION

Pay special attention to correctly positioning the bank angle sensor on the battery bracket (2).

Fit and tighten the screws (3).

WARNING

When refitting, connect the positive cable (+) first and then the negative cable (-).

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Connect the positive (+) cable by tightening the terminal screw (4). Connect the negative (-)cable by tightening the terminal screw (5).

Coat lead connections and terminals with neutral grease or Vaseline.

Refit the red protective cap (6).

Refit the rider seat, see page 108 (REMOVING THE RIDER SEAT).

CAUTION

When the battery is removed, the digital clock and red line setting will be reset to zero. See page 34 (MULTIFUNCTION COMPUTER) for instructions on how to set clock and red line.

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ADJUSTING THE HEADLIGHT BEAM VERTICALLY

WARNING

Do not use the vehicle if the lights are not functioning properly.

Do not use the vehicle if the headlight is adjusted incorrectly . This could temporarily blind oncoming cars, and also reduce the rider’s ability to see any obstacle along the road while riding at night.

It is always advisable to reduce speed when riding at night, so as to have the time necessary to avoid any obstacle and to adapt to the poorer visibility that inevitably results from darkness. Failure to observe this warning can cause you to collide with another object, with consequent risk of serious injury or even death.

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NOTE The procedure described here is in compliance with the Italian standard that establishes the maximum height of the headlight beam.

For vehicles used in other countries, you must conform with local regulations.

To quickly check the correct adjustment of the beam, place the vehicle on flat ground, 32.81 ft (10 m) away from a wall.

Turn on the low beam, sit on the vehicle and make sure that the beam projected on the wall is slightly under the horizontal line of the headlight (about 9/10th of the total height).

To adjust the headlight beam vertically:

Working from the rear of the front part of the fairing.

CAUTION

Do not force the screw beyond its limits.

Adjust the screw (1).

Turn the screw clockwise to adjust the right beam higher (upwards).

Turn the screw counterclockwise to a d j u s t t h e r i g h t b e a m l o w e r (downwards).

Repeat the process for the right beam.

WARNING

Make sure that the vertical adjustment of the headlight beam is correct.

HEADLIGHT SCREENING

In case headlights are to be taped (for using the vehicle on the track), it is r e c o m m e n d e d t o d i s c o n n e c t t h e connectors of the headlamps to prevent the lens from overheating because they are not cooled by air.

CAUTION

S e c u r e a n d i n s u l a t e p r e v i o u s l y disconnected wires so that they do not hinder handlebar movement and are insulated from water.

CAUTION

Restore electric connections before using the vehicle on the public road.

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ADJUSTING THE HEADLIGHT BEAM HORIZONTALLY

WARNING

Do not use the vehicle if the lights are not functioning properly. Do not use the vehicle if the headlight is adjusted incorrectly. This could temporarily blind oncoming cars, and also reduce the rider’s ability to see any obstacle along the road while riding at night. It is always advisable to reduce speed when riding at night, so as to have the time necessary to avoid any obstacle and to adapt to the poorer visibility that inevitably results from darkness. Failure to observe this warning can cause you to collide with another object, with consequent risk of serious injury or even death.

NOTE The terms “right” and “left” are referred to the rider seated on the vehicle in the normal riding position.

It is possible to adjust the horizontal position both to the right and to the left.

Working from the rear left side of the front fairing, turn the screw (2).

CAUTION

Do not force the screws beyond their limits.

Working from the rear side of the front part of the fairing.

With the screw (2) to the left side of the dashboard (left beam):

turn the screw clockwise to adjust the beam to the left;

turn the screw counterclockwise to adjust the left beam to the right.

With the screw (2) to the right side of the dashboard (right beam):

turn the screw clockwise to adjust the right beam to the right;

turn the screw counterclockwise to adjust the right beam to the left.

WARNING

M a k e s u r e t h a t t h e h o r i z o n t a l adjustment of the headlight beam is correct. Different jurisdictions have different requirements for horizontal headlight aiming. Make sure that you c o n f o r m w i t h t h e r u l e s o f t h e jurisdictions in which your vehicle is being used.

HEADLIGHT SCREENING

In case headlights are to be taped (for using the vehicle on the track), it is r e c o m m e n d e d t o d i s c o n n e c t t h e connectors of the headlamps to prevent the lens from overheating because they are not cooled by air.

CAUTION

S e c u r e a n d i n s u l a t e p r e v i o u s l y disconnected wires so that they do not hinder handlebar movement and are insulated from water.

CAUTION

Restore electric connections before using the vehicle on the public road.

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mi

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BULBS

 

 

C a r e f u l l y

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(MAINTENANCE).

 

 

WARNING

Do not use the vehicle if the lights are not functioning properly.

Do not use the vehicle if the headlight is adjusted incorrectly . This could temporarily blind oncoming cars, and also reduce the rider’s ability to see any obstacle along the road while riding at night.

It is always advisable to reduce speed when riding at night, so as to have the time necessary to avoid any obstacle and to adapt to the poorer visibility that inevitably results from darkness. Failure to observe this warning can cause you to collide with another object, with consequent risk of serious injury or even death.

WARNING

Risk of fire.

K e e p f u e l a n d o t h e r f l a m m a b l e substances away from the electrical components.

Before changing a bulb, turn the ignition switch (1) to the “ ” (OFF) position and wait a few minutes so that the bulb cools down.

Change the bulb wearing clean gloves or using a clean and dry cloth.

Do not leave fingerprints on the bulb, since these may cause its overheating and consequent breakage.

If you touch the bulb with your bare fingers, remove any fingerprints with alcohol in order to avoid any damage.

TAKE CARE TO AVOID DAMAGING THE ELECTRIC CABLES.

NOTE Before changing a bulb, check the fuses, see page 121 (CHANGING FUSES).

CHANGING THE DASHBOARD BULBS

In the unlikely event that the dashboard bulbs need changing, please see your Local aprilia Dealer. This operation is difficult and delicate, and should be entrusted to your local dealer.

CAUTION

The instrument panel is equipped with LED lighting and if a failure occurs the complete instrument panel will be replaced.

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CHANGING

THE HEADLIGHT BULBS

Carefully read page 129 (BULBS).

NOTE Before changing a bulb, check the fuses, see page 121 (CHANGING FUSES).

The headlight contains:

The headlight accommodates the following bulbs:

Two high-beambulbs (1).

Two low-beambulbs (2).

Two parking-lightbulbs (3).

The high - and low-beambulbs are identical. If the low beam is burned out and no spare bulb is available, it is possible to substitute thehigh-beambulb for the lowbeam bulb.

This should only be done to make it possible to ride a short distance at night to a shop where a new bulb can be obtained or home.

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To replace:

Place the vehicle on the stand, see page 58 (PLACING THE VEHICLE ON THE STAND).

HIGHAND LOW-BEAMBULBS

NOTE Disconnect one connector at a time to avoid confusing the various connectors when refitting.

When highand low-beambulb connectors must be removed simultaneously, mark them with their positions and make sure to refit them in the correct positions when assembling.

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CAUTION

Never pull on the wiring to disconnect a bulb connector.

Disconnect the connector (4).

Rotate the lockring counterclockwise and extract the bulb holder (5).

Fit a new bulb of equal rating.

Refit the bulb holder into the seat and rotate clockwise to lock in place.

Refit the connector (4).

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