Aprilia TUONO 1000 User Manual 2006

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CALIFORNIA EVAPORATIVE EMISSION SYSTEM

FOR STATE OF CALIFORNIA ONLY.

The system consists of:

1)Coal filter

2)Choke hold

3)Valve

4)Canister support plate

5)M6x20* flanged TE screw

6)4x8 tube

7)5.5x10 fuel line

8)D11.3 tie wrap

9)D10.1* tie wrap

10)D8* tie wrap 11)D9.1* tie wrap 12)D10.6 cable runner

7

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7

 

 

 

8

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5

8

 

 

 

 

 

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4

2

 

 

 

 

 

 

8

11

 

 

 

 

 

 

 

3

 

11

 

 

 

 

1

 

 

 

 

 

10

10

6

 

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aprilia s.p.a. - EMISSION CONTROL SYSTEM WARRANTY STATEMENT

YOUR WARRANTY RIGHTS

AND OBLIGATIONS

The California Air Resources Board and aprilia s.p.a. (hereinafter “aprilia”) are pleased to explain the emission control system warranty on your 1999 and later motorcycle. In California new motor vehicles must be designed, built and equipped to meet the State’s stringent antismog standards.aprilia must warrant the emission control system on your motorcycle for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your motorcycle.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, catalytic converter and engine computer. Also included may be hoses, belts, connectors and other emission-relatedassemblies.

Where a warrantable condition exists, aprilia will repair your motorcycle at no cost to you, including diagnosis, parts and labor.

MANUFACTURER’S EMISSIONS SYSTEM WARRANTY COVERAGE

Class I motorcycles (50 – 169 cm3): for a period of use of five (5) years or 12,000 kilometers (7,456 miles), whichever occurs first.

Class II motorcycles (170 – 279 cm3): for a period of use of five (5) years or 18,000 kilometers (11,185 miles), whichever occurs first.

Class III motorcycles (280 cm3 and larger): for a period of use of five (5) years or 30 , 0 0 0 k i lo m e t e r s ( 1 8,6 4 1 m i l es ) , whichever occurs first.

If an emission-relatedpart on your motorcycle is defective, the part will be repaired or replaced byaprilia. This is your emission control system DEFECTS WARRANTY.

OWNER’S WARRANTY

RESPONSIBILITIES

As the motorcycle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. aprilia recommends that you retain all receipts covering maintenance on your motorcycle, but aprilia cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

You are responsible for presenting your motorcycle to an aprilia dealer as soon as a problem arises. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

As the motorcycle owner, you should be aware that aprilia may deny your warranty coverage if your motorcycle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

If you have any questions regarding your warranty rights and responsibilities, you should contact aprilia USA, Inc., 10933 Crabapple Road, Suite 100, Roswell, GA 3007, or theCalifornia Air Resources Board at P.O. Box 8001, 9528 Telstar Avenue, El Monte, CA91734-8001.

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aprilia s.p.a. - LIMITED WARRANTY ON EMISSION CONTROL SYSTEM

aprilia s.p.a., Via G. Galilei, 1, 30033 Noale (VE) Italy (hereinafter “aprilia”) warrants that each new 1999 and afteraprilia motorcycle, that includes as standard equipment a headlight, taillight and stoplight, and is street legal:

A.is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and the California Air Resources Board; and

B.is free from defects in material and workmanship which cause such motorcycle to fail to conform with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for a period of use, depending on the engine displacement, of 12,000 kilometers (7,456 miles), if the motorcycle’s engine displacement is less than 170 cubic centimeters; of 18,000 kilometers (11,185 miles), if the motorcycle’s engine displacement is equal to or greater than 170 cubic centimeters but less than 280 cubic centimeters; or of 30,000 kilometers (18,641 miles), if the motorcycle’s engine displacement is 280 cubic centimeters or greater; or 5 (five) years from the date of initial retail delivery, whichever occurs first.

I.COVERAGE. Warranty defects shall be remedied during customary business hours at any authorizedaprilia motorcycle dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board. Any part or parts replaced under this warranty shall become the property ofaprilia.

In the State of California only, emission related warranted parts are specifically defined by the state’s Emission Warranty Parts List. These warranted parts are: carburetor and internal parts; intake manifold; fuel tank; fuel injection system; spark advance mechanism; crankcase breather; air cutoff valves; fuel tank cap for evaporative emission controlled vehicles; oil filler cap; pressure control valve; fuel/vapor separator; canister; igniters; breaker governors; ignition coils; ignition wires; ignition points; condensers, and spark plugs if failure occurs prior to the first scheduled replacement; and hoses, clamps, fittings and tubing used directly in these parts. Since emission related parts may vary from model to model, certain models may not contain all of these parts and certain models may contain functionally equivalent parts.

In the State of California only, Emission Control System emergency repairs, as provided for in the California Administrative Code, may be performed by other than an authorized aprilia dealer. An emergency situation occurs when an authorizedaprilia dealer is not reasonably available, a part is not available within 30 days, or a repair is not complete within 30 days. Any replacement part can be used in an emergency repair .aprilia will reimburse the owner for the expenses, including diagnosis, not to exceedaprilia’s suggested retail price for all warranted parts replaced and labor charges based onaprilia’s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate. The owner may be required to keep receipts and failed parts in order to receive compensation.

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II.LIMITATIONS. This Emission Control System warranty shall not cover any of the following:

A.Repair or replacement required as a result of

(1)accident,

(2)misuse,

(3)repairs improperly performed or replacements improperly installed,

(4)use of replacement parts or accessories not conforming to aprilia specifications which adversely affect performance and/or

(5)use in competitive racing or related events.

B.Inspections, replacement of parts and other services and adju stments required for required maintenance.

C.Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined.

III. LIMITED LIABILITY

A.The liability of aprilia under this Emission Control System Warranty is limited solely to the remedying of defects in material or workmanship by

an authorized aprilia motorcycle dealer a t i t s p l a ce o f b u s i n e s s d u r i n g customary business hours . This warranty does not cover inconvenience or loss of use of the motorcycle or transportation of the motorcycle to or from theaprilia dealer.

aprilia SHALL NOT BE LIABLE FOR ANY OTHER EXPENSES, LOSS OR D A M A G E , W H E T H E R D I R E C T , INCIDENTAL, CONSEQUENTIAL OR E XE MP L A R Y A R I S I N G I N CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THEaprilia MOTORCYCLE FOR ANY PURPOSE. SOME STATES DO NOT A L L O W T H E E X C L U S I O N O R LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.

B.NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY aprilia EXCEPT AS SPECIFICALLY SET FORTH HEREIN. ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO THE EXPRESS EMISSION CONTROL S YS T E M W AR R A N T Y T E R M S STATED IN THIS WARRANTY. THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.

C.No dealer is authorized to modify this aprilia Limited Emission Control System Warranty.

IV. LEGAL RIGHTS. THIS WARRANTY G I VE S YO U SP E CI F I C L EG A L RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

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V.THIS WARRANTY IS IN ADDITION TO THE aprilia LIMITED MOTORCYCLE WARRANTY.

VI. ADDITIONAL INFORMATION.Any replacement part that is equivalent in performance and durability may be used in the p erformance of a ny maintenance or repairs. However, aprilia is not liable for these parts. The o w n e r i s r e s p o n s i b l e f o r t h e p e r f o r m a n c e o f a l l r e q u i r e d maintenance. Such maintenance may b e p e r f o r m e d a t a s e r v i c e establishment or by any individual. The warranty period begins on the date the motorcycle is delivered to an ultimate purchaser.

aprilia s.p.a. via G. Galilei, 1

30033 Noale (VE) Italy

aprilia USA, Inc.

109 Smoke Hill Lane, Suite 190 Woodstock, GA 30188

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GENERAL INSTRUCTIONS

The operations preceded by this symbol must be repeated also on the opposite side of the vehicle.

If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order.

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

WARNING

The competition adjustment must be used in organized racing or circular course competitive event, under the auspices of a recognized sanctioning body or by permit issued by the local governmental authority having jurisdiction. It is strictly forbidden to use the competition adjustment while riding the vehicle on public streets, roads, or highways.

NOTE Immediately after purchasing the vehicle, write down the identification data p r o v i d e d i n t h e S P A RE P A R T S IDENTIFICATION LABEL in the table below. This label is positioned on the left side of the frame; to be able to read it, remove the rider seat, see page 108 (REMOVING THE RIDER SEAT).

This information indicates:

YEAR = year of manufacture (Y, 1, 2, …);

I.M. = modification code (A, B, C, …);

COUNTRY CODE = country of approval (I, UK, A, …).

and must be provided to the Local aprilia Dealer as reference information for the purchase of spare parts or specific accessories of the model you have purchased.

In this manual the various versions are indicated by the following symbols:

catalytic version

optional

VERSION:

I

Italy

SGP

Singapore

UK

United

SLO

Slovenia

 

Kingdom

 

 

A

Austria

IL

Israel

P

Portugal

ROK

South Korea

SF

Finland

MAL

Malaysia

B

Belgium

RCH

Chile

D

Germany

HR

Croatia

F

France

AUS

Australia

E

Spain

USA

United States

 

 

 

of America

GR

Greece

BR

Brazil

NL

Holland

RSA

South Africa

CH

Switzerland

NZ

New Zealand

DK

Denmark

CDN

Canada

J

Japan

 

 

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CONTENTS

 

FOREWORD..............................................

2

INTRODUCTION.......................................

2

SAFETY WARNINGS ................................

3

GENERAL SAFETY RULES ......................

3

CARBON MONOXIDE .............................................

3

HOT COMPONENTS...............................................

3

USED ENGINE OIL..................................................

3

BRAKE FLUID...........................................................

4

CLUTCH FLUID........................................................

4

COOLANT.................................................................

4

BATTERY HYDROGEN GAS AND

 

ELECTROLYTE........................................................

4

WARNING - PRECAUTIONS - GENERAL

 

ADVICE ....................................................

5

REPORTING DEFECTS THAT AFFECT SAFETY5

ROAD REGULATIONS

 

AND USE OF THE VEHICLE..................................

5

NOISE EMISSION WARRANTY.............................

5

INFORMATION ON THE NOISE AND EXHAUST

GAS EMISSION CONTROL SYSTEM...................

5

TAMPERING WARNING .........................................

5

PROBLEMS THAT MAY AFFECT VEHICLE

 

EMISSIONS ..............................................................

6

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

 

(FRAME NUMBER)..................................................

6

INFORMATION CONTAINED IN THE VEHICLE

 

IDENTIFICATION NUMBER....................................

6

DIGIT MEANING.......................................................

7

POSITION OF THE ADHESIVE WARNING

 

LABELS .....................................................................

8

ADHESIVE WARNING LABELS CHART...............

9

CALIFORNIA EVAPORATIVE EMISSION

 

SYSTEM..................................................................

11

APRILIA S.P.A. - EMISSION CONTROL SYSTEM

WARRANTY STATEMENT ...................................

12

MANUFACTURER’S EMISSIONS SYSTEM

 

WARRANTY COVERAGE.....................................

12

OWNER’S WARRANTY

 

RESPONSIBILITIES...............................................

12

APRILIA S.P.A. - LIMITED

 

WARRANTY ON EMISSION

 

CONTROL SYSTEM..............................................

13

GENERAL INSTRUCTIONS ....................

16

CONTENTS ............................................................

17

BASIC SAFETY RULES ........................................

20

CLOTHING..............................................................

25

ACCESSORIES......................................................

26

LOAD.......................................................................

26

ARRANGEMENT OF THE MAIN

 

ELEMENTS ............................................

28

ARRANGEMENT OF THE

 

INSTRUMENTS/CONTROLS ...................

30

Instruments and indicators...................

31

INSTRUMENT AND INDICATOR TABLE............

32

MULTIFUNCTION COMPUTER...........................

34

SERVICE INTERVAL.............................................

40

ALARM DISPLAY...................................................

40

CONTROLS ............................................

41

CONTROLS ON THE LEFT HAND GRIP............

41

CONTROLS ON THE RIGHT HAND GRIP .........

42

IGNITION SWITCH ................................................

43

STEERING LOCK ..................................................

43

UNLOCKING/LOCKING THE PASSENGER

 

SEAT/SEAT COVER..............................................

44

GLOVE/TOOL KIT COMPARTMENT...................

45

LUGGAGE RACK FASTENINGS.........................

45

SPECIAL TOOLS ..................................................

46

MAIN COMPONENTS .............................

47

FUEL........................................................................

47

LUBRICANTS .........................................................

48

BRAKES..................................................................

50

DISC BRAKES........................................................

51

FRONT BRAKE ......................................................

52

REAR BRAKE.........................................................

53

CLUTCH..................................................................

55

ADJUSTING THE CLUTCH LEVER.....................

58

ADJUSTING THE FRONT BRAKE LEVER.........

58

ADJUSTING THE SHIFT PEDAL .........................

58

ADJUSTING THE REAR BRAKE PEDAL............

59

ADJUSTING THE CLEARANCE

 

OF THE REAR BRAKE LEVER............................

59

COOLANT...............................................................

60

TIRES......................................................................

62

AUTOMATIC LIGHTS ON.....................................

63

MUFFLER/EXHAUST SILENCER........................

63

INSTRUCTIONS FOR USE......................

64

GETTING ON AND OFF THE VEHICLE..............

64

PRE-RIDECHECKS..............................................

66

PRE-RIDECHECKS CHART................................

67

STARTING..............................................................

68

RIDING....................................................................

70

RUNNING-IN ..........................................................

74

STOPPING..............................................................

75

PARKING................................................................

75

PLACING THE VEHICLE ON THE STAND.........

77

SUGGESTIONS TO PREVENT THEFT..............

77

MAINTENANCE ......................................

79

REGULAR SERVICE INTERVALS CHART ........

81

MAINTENANCE RECORD....................................

83

IDENTIFICATION DATA........................................

86

JOINTS WITH CLICK CLAMPS AND WITH

 

SCREW-TYPECLAMPS.......................................

86

AIR CLEANER........................................................

87

CHECKING THE ENGINE OIL LEVEL AND

 

TOPPING UP..........................................................

89

CHECKING THE SIDE STAND ............................

91

CHECKING THE FUNCTIONING OF THE

 

SAFETY SWITCH ON THE SIDE STAND...........

91

CHECKING THE SWITCHES...............................

92

INSPECTING THE FRONT

 

AND REAR SUSPENSIONS.................................

93

FRONT SUSPENSION..........................................

93

STEERING DAMPER ............................................

95

REAR SUSPENSION ............................................

95

CHECKING THE BRAKE PAD WEAR.................

97

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CHECKING THE STEERING................................

98

CHECKING THE SWINGARM PIVOT..................

98

ASSEMBLING THE PINS FOR THE REAR

 

SUPPORT STAND ................................................

99

PLACING THE VEHICLE ON THE REAR

 

SUPPORT STAND ................................................

99

PLACING THE VEHICLE ON THE FRONT

 

SUPPORT STAND ..............................................

100

FRONT WHEEL....................................................

100

REAR WHEEL ......................................................

102

DRIVE CHAIN.......................................................

105

REMOVING THE RIDER SEAT..........................

108

LIFTING THE FUEL TANK ..................................

108

REMOVING THE SIDE FAIRINGS.....................

109

REMOVING THE SIDE FAIRINGS.....................

113

REMOVING THE REARVIEW MIRRORS .........

113

REMOVING THE FRONT BRAKE CALIPERS..114

REMOVING THE SIDE STAND..........................

115

ADJUSTING THE THROTTLE CONTROL ........

118

SPARK PLUGS.....................................................

119

CHANGING FUSES .............................................

121

BATTERY..............................................................

123

BATTERY STORAGE ..........................................

124

CHECKING AND CLEANING THE

 

TERMINALS..........................................................

124

REMOVING THE BATTERY ...............................

125

CHECKING THE ELECTROLYTE LEVEL.........

125

RECHARGING THE BATTERY ..........................

125

INSTALLING THE BATTERY..............................

126

ADJUSTING THE HEADLIGHT BEAM

 

VERTICALLY ........................................................

127

HEADLIGHT SCREENING..................................

127

ADJUSTING THE HEADLIGHT BEAM

 

HORIZONTALLY ..................................................

128

HEADLIGHT SCREENING..................................

128

BULBS ...................................................................

129

CHANGING THE DASHBOARD BULBS ...........

129

CHANGING THE HEADLIGHT BULBS..............

130

REPLACING THE FRONT AND REAR DIRECTION

INDICATOR BULBS.............................................

131

REPLACING THE LICENSE PLATE LIGHT

 

BULB......................................................................

132

TRANSPORT........................................

133

DRAINING THE FUEL TANK..............................

133

CLEANING ...........................................

134

LONG PERIODS OF INACTIVITY......................

135

TECHNICAL DATA ...............................

137

LUBRICANT CHART............................................

141

WIRING DIAGRAM TUONO 1000......................

142

WIRING DIAGRAM KEY - TUONO 1000...........

143

OFFICIAL DEALERS AND SERVICE

 

CENTERS .............................................................

144

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BASIC SAFETY RULES

The instructions given below cover normal operation of your vehicle and must be carefully observed. By following these rules you will enhance your own safety and the safety of those around you. You will also maximize the life and utility of your vehicle.

Two-wheeledvehicles obviously do not provide some of the protection provided by automobiles, therefore it is essential that you wear appropriate protective clothing. In particular, never operate your vehicle without wearing your helmet, gloves, eye protection, a heavy jacket, sturdy footwear, and sturdy full length pants.

However, do not assume that even the best clothing and helmet will protect you in the event of an upset or a crash with another vehicle. At best, this gear provides some protection from scrapes and scratches, but very little, if any, impact protection.

Be sure that you meet all the requirements prescribed by local law, including driver’s license, minimum age, training, insurance, taxes, vehicle registration, license plate, etc.

When you first receive your vehicle, practice by riding in areas where there is little traffic. Do not attempt to ride in heavy traffic until you are thoroughly experienced and riding your vehicle has become second nature to you.

Although this vehicle is legal for use on freeways and expressways, it is advisable to not ride on these high-speedhighways until you are thoroughly familiar with your vehicle, and have attained a high degree of skill in its operation.

A new vehicle must be carefully broken in, see page 74 (RUNNING-IN).

Before starting the engine, make sure that the brakes, clutch, transmission and throttle controls function properly and that the fuel and oil supply is adequate.

The exhaust system, brakes, and some other parts of the vehicle become very hot during operation. Do not touch any of these parts.

Some medicines or drugs, whether illegal or prescription, and alcohol significantly increase the risk of accidents. Do not ride while you are under the influence of alco hol or d rugs, b e the y ill icit o r prescription.

Make sure you are in good physical condition and not ill before riding your vehicle. Do not ride your vehicle when you are particularly tired or fatigued. Alcohol, drugs and fatigue are leading causes of vehicle accidents.

Many accidents are caused by the rider’s inexperience and lack of training. Do not ride your vehicle until you have received training from a recognized training organization such as the Motorcycle Safety Foundation. Remember that riding a twowheeled vehicle, though easy and fun, is quite different from driving a car. Do not assume that you can operate your vehicle safely just because you are a competent automobile driver.

Never lend your vehicle to others unless you are sure that they are competent and properly licensed vehicle operators.

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