Aprilia TUONO 1000 User Manual 2006
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DISC BRAKES

WARNING

As mentioned above, the brakes are the most important safety system on your vehicle. For your safety, they must be in perfect condition, so they should be checked every time you ride your vehicle.

O i l o r o t h e r f l u i d o n a d i s c w i l l contaminate the brake pads. Dirty pads must be discarded and replaced, a dirty or oily disc must be cleaned with a high quality degreaser.

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

Have your Local aprilia Dealer check the levels of the brake fluid in the reservoirs after the first 600 mi (1,000 km).

Arrange with your Local aprilia Dealer to flush the systems and completely change the brake fluid once every two years.

NOTE This vehicle is fitted with front and rear disk brakes. Each braking system is operated by an independent hydraulic circuit.

The front brake is a twin-diskbrake (one disk on either side of the wheel).

The rear brake uses a single disk (fitted on the right side of the wheel).

The information provided below applies to both braking systems.

The brake fluid level decreases gradually as the brake pads wear down.

The front brake fluid reservoir is mounted near the front brake lever coupling.

The rear brake fluid reservoir is positioned under the right fairing; to access it, remove the right fairing, see page 80 (REMOVING THE SIDE FAIRINGS).

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 brake disks checked by an Official aprilia dealer after the first 625 mi (1,000 km) and every 6,250 mi (10,000 km) thereafter.

Before each ride, check the brake fluid level in both reservoirs - see page 52 (FRONT BRAKE) and page 53 (REAR BRAKE), and check the brake pads for wear - see page 97 (CHECKING THE BRAKE PAD WEAR).

Have brake fluid changed every two years by an Official aprilia dealer.

WARNING

Never use your vehicle if any portion of either brake system is leaking.

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FRONT BRAKE

CHECKING THE SYSTEM

NOTE Carry out these checks only on a firm, flat surface such as a concrete garage floor.

uPlace the vehicle in vertical position, keeping the handlebar in the direction of travel.

uMake sure that the fluid contained in the reservoir exceeds the “MIN” mark stamped on the brake reservoir (1).

MIN = minimum level.

If the fluid does not reach the “MIN” mark:

CAUTION

When the disc pads wear out, the level of the fluid decreases progressively to compensate for their wear.

uCheck front brake pad wear, page 97 (CHECKING THE BRAKE PAD WEAR) and front disc wear.

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If the pads and/or the disc do not need replacing:

uTop up the reservoir, see below (TOPPING UP).

TOPPING UP

Carefully read page 50 (BRAKES) and page 51 (DISC BRAKES).

CAUTION

Danger of brake fluid overflow. Do not use the brake lever when the screws (2) are loose or, especially, when the brake fluid tank cap has been removed.

uPlace the vehicle in vertical position, keeping the handlebar in the direction of travel.

uUsing a short Phillips screwdriver, loosen the three screws (2).

uRaise and remove the cover (3) together with the screws (2) and the gasket (4).

WARNING

Avoid any prolonged exposure of the brake fluid to air.

The brake fluid is hygroscopic and when in contact with air it absorbs its humidity.

Leave the brake fluid reservoir open ONLY for the time necessary for topping up.

NOTE In order not to spill the brake fluid while topping up, keep the fluid in the reservoir parallel to the reservoir rim, and do not shake the vehicle.

CAUTION

While topping up, never pour too much fluid. Fill up to the max. level only with new brake pads.

CAUTION

If topped up to the max. level with worn pads, the brake fluid will overflow when you change the pads at a later time.

CAUTION

Use only DOT 5 or 4 fluid taken from a clean, sealed container. Never reuse used brake fluid.

CAUTION

If you use a container or funnel for topping up, make sure that it is perfectly clean. Any foreign matter getting into the brake reservoir may lead to severe damage.

52 use and maintenanceTUONO 1000 USA

WARNING

Do not add any additives or other substances to the brake fluid.

uTop up the reservoir (1) with brake fluid, see page 141 (LUBRICANT CHART) until it exceeds the "MIN" level mark.

uReplace the cover (4) together with the screws (3) and the gasket (6).

uScrew and tighten the three screws (3).

CAUTION

After servicing the brakes, always check that they are working properly. If the stroke of the lever 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 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.

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REAR BRAKE

CHECKING THE SYSTEM

NOTE Carry out these checks only on a firm, flat surface such as a concrete garage floor.

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

NOTE If the reservoir is dirty, wipe it with a clean cloth so that you can see the “MIN” and “MAX” marks.

uKeep the vehicle vertical, so that the fluid contained in the reservoir (1) is parallel to the filler cup (2).

MIN = minimum level.

MAX = maximum level.

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If the fluid does not reach the “MIN” mark:

CAUTION

When the disc pads wear out, the level of the fluid decreases progressively to compensate for their wear.

uCheck rear brake pad wear, page 97 (CHECKING THE BRAKE PAD WEAR)

and rear disc wear.

If the pads and/or the disc do not need replacing:

uTop up the reservoir, see below (TOPPING UP) .

TOPPING UP

Carefully read page 50 (BRAKES) and page 51 (DISC BRAKES).

uRemove the right fairing, see page 109 (REMOVING THE SIDE FAIRINGS).

uLoosen the screw (3) completely.

uSlightly move the complete reservoir (1) outwards.

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CAUTION

Do not operate the rear brake pedal with the reservoir filler cap (2) removed. This will cause brake fluid to squirt out and spill.

uLoosen and remove the reservoir filler cap (2).

WARNING

Avoid any prolonged exposure of the brake fluid to air. The brake fluid is hygroscopic and when in contact with air it absorbs its humidity. Leave the brake fluid reservoir open ONLY for the time necessary for topping up. In order not to spill the brake fluid while topping up, keep the fluid in the reservoir parallel to the reservoir rim.

u Remove the gasket (4).

CAUTION

When topping up, never exceed the “MAX” level. Top up to “MAX” only when new pads are installed. Do not fill the reservoir to “MAX” with worn pads; this will cause fluid to overflow when you change the pads at a later time.

NOTE In order to fill the reservoir to the “MAX” level, top up until the “MAX” mark is parallel with the brake fluid reservoir top parallel to the ground.

WARNING

Use only DOT 5 or 4 fluid taken from a clean, sealed container. Never reuse used brake fluid.

CAUTION

If you use a container or funnel for topping up, make sure that it is perfectly clean. Any foreign matter getting into the brake reservoir may lead to severe damage.

WARNING

Do not add any additives or other substances to the brake fluid.

uTop up the reservoir with brake fluid, until the fluid reaches the “MAX” mark.

uReplace the gasket (4) in its seat correctly.

CAUTION

Do not tilt the reservoir (1) even if the cap (2) is tightened. This might let air in the circuit and the brake system would be impaired.

uReplace and tighten the reservoir filler cap (2).

uReplace the reservoir (1) in its seat correctly.

uReplace and tighten the screw (3).

uReplace the right fairing, see page 109 (REMOVING THE SIDE FAIRINGS).

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