Aprilia TUONO 1000 User Manual 2006
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ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND

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

Place the pin (1) on the appropriate seat on the swingarm.

Insert and tighten the screw (2) in the appropriate threaded hole (3) in the swingarm.

PLACING THE VEHICLE ON THE REAR SUPPORT STAND

Assemble the pins for the rear support stand , see above (ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND).

NOTE Have someone help you keep the vehicle vertical with the two wheels on the ground.

Slacken the knob (5).

Shift the fork-shapedsupport (4) so that its width matches the distance between the two pins (1) fitted to the swingarm.

Tighten the knob (5).

Slide both fork-shapedseats (4) of the stand (6) underneath the pins (1) fitted to the vehicle simultaneously.

Place one foot on the rear end of the stand (6).

Push the stand (6) downwards until it reaches the end of its stroke (see figure).

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.

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PLACING THE VEHICLE ON THE FRONT SUPPORT STAND

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) .

Lift the front part of the stand (1) and insert each of its ends (2) into the holes

(3) in the bottom of the front fork.

Rest one foot on the front part of the stand (1).

Push the stand (1) downwards until it reaches the end of its stroke (see figure).

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.

FRONT WHEEL

WARNING

The disassembly and reassembly of the front wheel can be difficult for those unfamiliar with vehicle maintenance. You may wish to have your Local aprilia D e a l e r c a r r y o u t t h e s e operations.

If you wish to perform these operations y o u r s e l f , c a r e f u l ly r e a d p a ge 7 9 (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.

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. You must use the appropriate front and rear support stands

(1) (2) to remove the front wheel.

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DISASSEMBLY

Remove the front brake calipers, see page 114 (REMOVING THE FRONT BRAKE CALIPERS) .

Place a support (1) under the tire to hold the wheel in place once released.

CAUTION

Never touch the front brake lever after removing the brake calipers from the discs. 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.

Place a support (1) under the front tire, so as to keep the wheel in its position after loosening it.

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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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