Aprilia TUONO 1000 User Manual 2006
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MAINTENANCE

Carefully read page 2 (FOREWORD) and (INTRODUCTION), page 3 [SAFETY WARNINGS] and (GENERAL SAFETY R U L E S ) , p a g e 5 [ W AR N I N G - PRECAUTIONS - GENERAL ADVICE].

WARNING

Fire hazard.

Keep fuel and other flammable substances away from the electrical components. Before beginning any maintenance operation or any inspection of the vehicle, stop the engine, remove the key (1) from the ignition switch (2), wait until the engine and the exhaust system have cooled down and if possible lift the vehicle by means of the proper equipment, on firm and flat ground. Before proceeding, make sure that the room in which you are working is properly ventilated.

Be careful to avoid hot parts of the engine and exhaust system. They are hot enough to cause serious burns.

Avoid the temptation to hold any part of the vehicle in your mouth. The coatings, platings and components used are not edible and, in some cases, are noxious or even toxic.

WARNING

In general, reassembly is performed in the reverse order of the disassembly instructions given here.

For some maintenance operations, especially those in which your hands are likely to come in contact with coolant, engine oil, gasoline, or brake fl ui d, i t i s ad vis able to use thin disposable gloves, such as those made of latex, rubber or nitrile.

The routine maintenance operations described in this manual can usually be performed by the user. However, in some cases, specific tools and technical expertise may be required.

Do not hesitate to contact your Local aprilia Dealer who has all the latest factory information and tools to properly service your vehicle.

Remember that many service operations, if done improperly, can be very hazardous. If you have any questions about your ability to carry out the operations described here, contact your Local aprilia.

In all cases, personally carry out the “preliminary checking operations” after any maintenance, see page 67 (PRE-RIDECHECKS CHART).

use and maintenance TUONO 1000 USA 79

WARNING

Remember that tightening torque settings of all fasteners on the wheels, b r a k e s , a x l e s , s u s p e n s i o n a r e extremely important to ensure safety, a n d m u s t b e m a i n t a i n e d a t t h e prescribed values.

Check the tightening torque settings of the fasteners regularly, and always use a torque wrench when installing them.

Failure to observe this warning could cause the loosening and subsequent loss of critical fasteners, which could cause a wheel to lock or cause other handling problems with consequent overturning, and the risk of serious injury or even death.

WARNING

F a s t e n e r s m u s t b e n e i t h e r overtightened or undertightened. If they are overtightened, the threads may be damaged and the fasteners will be d e s t r o y e d , w h e r e a s i f t h e y a r e undertightened, they can vibrate and come off. This could cause a serious accident and result in serious injury or death.

1

CAUTION

I f t h e w o r d “ S E R V I C E ” ( 1 ) i s d i s p l a y e d d u r i n g n o r m a l e n g i n e operation, it means that the Engine Control Unit has detected a fault.

In most cases, the engine will keep running, but with reduced performance levels. At any rate, contact an aprilia Official dealer immediately.

CAUTION

After covering the first 625 mi (1,000 km) and every 6,250 mi (10,000 km) thereafter, the “ SERVICE” symbol

(1) appears on the right display.

In this case have a Local aprilia Dealer perform all service operations as indicated in the scheduled maintenance chart, see page 81 (REGULAR SERVICE INTERVALS CHART).

80 use and maintenanceTUONO 1000 USA

REGULAR SERVICE INTERVALS CHART

T H E SE O P ER A T I O N S MA Y B E CARRIED OUT BY YOUR Local aprilia Dealer, OR BY THE OWNER OF THE VEHICLE.

KEY

c= check and clean, adjust, lubricate or change, if necessary;

d =

clean;

e =

change;

f =

adjust.

CAUTION

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

(*)= Check at least once a week and at the specified intervals.

 

 

After running-

Every 3,125 mi

Every 6,250 mi

Every 12,500

Component

in [625 mi

(5,000 km) (only

(10,000 km) or

mi (20,000 km)

 

 

(1,000 km)]

for racing use

12 months

or 24 months

Spark plug

 

e

c

e

 

 

 

 

 

 

Air filter

 

e

c

e

 

 

 

 

 

 

Engine oil filter

e

e

e

 

 

 

 

 

 

 

Engine oil filter (on oil tank)

d

d

 

d

 

 

 

 

 

 

Light operation/direction

 

 

c

 

 

 

 

 

 

 

Light system

c

 

c

 

 

 

 

 

Safety switches

 

 

 

 

 

 

 

 

 

 

 

 

Clutch fluid

c

c

c

 

 

 

 

 

 

 

Brake fluid

c

c

c

 

 

 

 

 

 

 

Coolant

c

c

 

c

 

 

 

 

 

 

Engine oil

e

e

e

 

 

 

 

 

 

 

TIRES

c

 

c

 

 

 

 

 

 

 

Tire pressure (*)

f

 

f

 

 

 

 

 

 

 

Error warning light (on

 

at every startup: c

 

instrument panel)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Drive chain tension and

 

every 625 mi (1,000 km): c

 

lubrication

 

 

 

 

 

 

 

 

 

 

 

 

Brake pad wear

c

every 625 mi

before each ride and every

(1,000 km): c

1,250 mi (2,000 km):c

 

 

 

 

 

 

 

 

 

use and maintenance TUONO 1000 USA 81

THESE MAINTENANCE OPERATIONS SHOULD ONLY BE PERFORMED BY YOUR Local aprilia Dealer.

KEY

c= check and clean, adjust, lubricate or change, if necessary;

d =

clean;

e =

change;

f =

adjust.

(*) only for versions with magnesium wheels: check that rim paint is in good condition.

CAUTION

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

 

After running-in

Every 3,125 mi

Every 6,250 mi

Every 12,500 mi

Component

[625 mi

(5,000 km) (only for

(10,000 km) or 12

(20,000 km) or 24

 

(1,000 km)]

racing use

months

months

Rear shock absorber

 

c

 

c

 

 

 

 

 

Gearbox

 

every 6,250 mi

 

 

 

(10,000 km): c

 

 

 

 

 

 

 

 

 

 

 

Transmission cables and controls

c

c

c

 

Rear suspension linkage bearings

 

 

 

c

Steering bearings and steering

c

c

c

 

clearance

 

 

 

 

 

 

 

 

 

 

Wheel bearings

 

c

c

 

 

 

 

 

 

Brake discs

c

c

c

 

General running of the vehicle

c

c

c

 

Adjusting the valve clearance

 

f

 

f

 

 

 

 

 

Braking systems

c

c

c

 

Cooling system

 

c

c

 

Clutch fluid

 

every 12 months: e

 

 

 

 

every 24 months: e

Brake fluid

 

 

 

Coolant

 

 

 

 

 

 

 

 

Fork oil

 

 

after the first 6,250 mi (10,000 km) and

 

 

then every 12,500 mi (20,000 km):e

 

 

 

Fork oil seals

 

 

after the first 18,650 mi (30,000 km) and

 

 

then every 12,500 mi (20,000 km):c

 

 

 

Brake pads

 

if worn:

e

 

Wheels/Tires (*)

c

c

c

 

 

 

Nut, bolt, screw tightening

 

 

 

 

 

Cylinder synchronization

c

 

c

 

Suspensions and track alignment

c

c

 

c

 

 

 

 

 

Final transmission (chain, rear

 

c

c

 

sprocket, front sprocket)

 

 

 

 

 

 

 

 

 

 

 

Fuel pipes

 

 

c

every 4 years:e

Clutch wear

 

c

 

 

Pistons

 

c

 

 

82 use and maintenanceTUONO 1000 USA