Aprilia TUONO 1000 User Manual 2006
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REMOVING THE SIDE FAIRINGS

Remove the rider seat, see page 108 (REMOVING THE RIDER SEAT). Loosen and remove the screw (1). Loosen and remove the screw (2) (remove the front screw).

CAUTION

Handle plastic and painted components w i t h c a r e t o a v o i d s c r a p i n g o r damaging.

Remove the side fairing (3).

NOTE Make sure that the rear fittings are positioned correctly when refitting. Repeat these operations to remove the other side fairing.

NOTE The passenger seat lock or passenger seat cover will remain attached to the left side fairing.

To separate them, disconnect the Bowden cable from the lock on the inside of the side fairing.

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REMOVING THE REARVIEW MIRRORS

Place the vehicle on the center stand on firm and level ground.

Lift the protection element (1).

CAUTION

Support the rearview mirror (4) or it may accidentally fall down.

Hold the screw (2) and loosen the nut (3) completely.

CAUTION

Handle plastic and painted components w i t h c a r e t o a v o i d s c r a p i n g o r damaging.

Remove the rearview mirror (4).

NOTE Repeat these operations to remove the other rearview mirror.

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WARNING

After reassembly, correctly adjust the rearview mirrors and tighten the nuts so that the mirrors are secure. Failure to observe this warning can prevent you from seeing danger approaching from behind and lead to a serious accident.

After refitting:

Adjust the inclination of the rearview mirrors correctly.

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REMOVING THE FRONT BRAKE CALIPERS

WARNING

The disassembly and reassembly of the front brake calipers 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).

The front brake system is equipped with two separate calipers, one on the left and one on the right side of the vehicle.

The following information may refer to only one brake caliper but is applicable to both.

While disassembling and reassembling the front brake calipers, pay extra care not to damage the brake lines, discs or pads.

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.

Place the vehicle on the front wheel stand, see page 100 (PLACING THE VEHICLE ON THE FRONT SUPPORT STAND) .

Rotate the wheel manually, so that the space between two spokes of the rims lines up with the brake caliper.

Have a helper steady the handlebar in the straight ahead position.

Brake caliper screw (1) tightening torque setting: 36.16 ftlb (50 Nm).

Remove the two screws (1) that fasten the front brake caliper (2).

CAUTION

Never touch the front brake lever after removing the brake caliper from the disc. 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.

Remove the brake caliper (2) from the disc, leaving it attached to its line (3).

Operate on the second brake caliper:

Repeat the operations marked .

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REASSEMBLY

WARNING

Keep your fingers clear. Avoid getting them caught between the wheel, the caliper or the fork. Do not attempt to align the holes in the caliper using your fingers. Failure to observe this warning can cause serious injury.

Insert the brake caliper (2) over the disc and place it so that its fastening holes and the holes on the support are aligned.

WARNING

When reassembling the brake caliper, replace the caliper screws (1) with two new screws of the same type.

Tighten the two screws (1) to the appropriate torque setting.

Brake caliper screw (1) tightening torque setting: 36.16 ftlb (50 Nm).

Operate on the second brake caliper:

Repeat the operations marked .

 

Remove the front support stand

,

see page 100 (PLACING THE VEHICLE

ON THE FRONT SUPPORT STAND)

.

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.

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REMOVING THE SIDE STAND

Carefully read page 79 (MAINTENANCE).

It is advisable to remove the side stand if the vehicle is to be used on closed course competition. When removing the side stand, you must remove the stand (1) complete with:

springs (2);

support (3);

safety switch (4).

WARNING

Failure to remove the side stand before using your vehicle on closed course competition can result in reduced cornering clearance. This could lead to a serious crash, which can result in serious injury or even death.

NOTE Removingthe safety switch (4) disconnects the electrical circuit, and your vehicle’s engine will not run with the transmission in gear.

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You must restore the circuit function by connecting the wiring device (6) (aprilia part # 8127544), which is available at yourLocal aprilia Dealer, to the connector (5).

If the vehicle is used on closed course competition, safety pegs (7) are available for installation on the rider footrests to avoid removal of the side stand.

WARNING

Removal of the safety pegs (7) fitted to the rider footrests is only allowed after removal of the side stand.

CAUTION

Never lean the vehicle against walls or lay it on the ground. This could lead to the vehicle falling over, causing damage to the vehicle and injury to yourself or other bystanders.

To park the vehicle without the stand only the rear support stand may be used.

WARNING

Never disconnect or remove the safety switch (4) without also removing the stand. Disconnecting or removing the safety switch (4) only makes it possible to start the vehicle and ride off with an extended stand which may result in upset, and serious injuries or even death to the rider or bystanders, and damage to the vehicle.

To remove the side stand:

Remove the left side cover, see page 113 (REMOVING THE SIDE FAIRINGS).

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

NOTE U s e a t i e - w r a p ( 7 ) f o r reassembly.

CAUTION

Do not force cables, tubes, lines, connectors and wires.

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

Disconnect the electric connector (10) from the connector (5).

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Connect the wiring (6) (aprilia part # 8127544) [in place of the electric connector (10)].

Withdraw the cable (9) completely.

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

Refit the left side fairing, see page 113 (REMOVING THE SIDE FAIRINGS).

NOTE Support the stand, in order to prevent it from accidentally falling down.

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Torque wrench setting for screws (11) and (13): 40 Nm (4 kgm).

Loosen and remove the screw (11) and the washer (12).

Loosen and remove the screw (13) while holding the nut (15) at the rear end with a wrench.

Remove the stand (1) complete with:

springs (2);

bracket (3);

stand switch (4).

Refit the screw (13), the washer (14) and the nut (15) and tighten to the specified torque setting.

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NOTE Store away the complete stand, the screw (11) and the washer (12) together. This way, you will be able to refit them correctly when you intend to use the vehicle on public roads.

Refit the left side fairing, see page 109 (REMOVING THE SIDE FAIRINGS).

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ADJUSTING

THE THROTTLE CONTROL

C a r e f u l l y

r e a d

p a g e 7 9

(MAINTENANCE).

 

 

This vehicle is equipped with two throttle cables.

The following information may refer to just one throttle cable but applies to both throttle cables.

WARNING

If the throttle sticks open, it may cause a collision with another vehicle, or an upset.

If the throttle sticks, kill the engine with the engine stop switch located on the right handlebar.

Do not attempt to restart the engine until the throttle has been repaired and works perfectly. Failure to observe this warning can lead to a runaway resulting in serious injuries or even death.

If any fastener in the throttle system becomes loose, you will also lose control of your vehicle.

Either situation can lead to an upset or collision, which can result in serious injury or death.

Your vehicle is equipped with a double cable throttle. One cable opens the throttle when you rotate the throttle grip towards you; the other closes the throttle when you rotate the grip away from you. It is essential, when you release the throttle grip, that it automatically return to the idle position.

This double cable arrangement enhances safety by providing for positive closing of the throttle.

WARNING

In the event of a throttle sticking emergency, always kill the engine using the engine stop switch located near the throttle grip on the right handlebar. Never use your vehicle if the throttle does not automatically fully return to the idle position when the throttle grip is released. Contact your Local aprilia Dealer for repairs. Failure to observe this warning can lead to a serious accident and result in injury or even death.

CAUTION

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 throttle cables after the first 600 mi (1,000 km) and thereafter every 6,250 mi (10,000 km).

The play of the throttle cable must be between 0.08 – 0.12 in (2 – 3 mm), measured at the edge of the grip, see the illustration above.

To adjust the cable:

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

Pull back the rubber boot (1). Loosen the lock nut (2).

Rotate the adjuster (3) so as to obtain the proper play.

After the adjustment, tighten the lock nut

(2) and check the play again. Replace the rubber boot (1).

Repeat the adjustment for the second cable.

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