Aprilia TUONO 1000 User Manual 2006

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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

MAINTENANCE RECORD

Owner Name

Owner Address

Owner Telephone Number

Vehicle Identification Number (V.I.N.) (frame number) see page 86 (IDENTIFICATION DATA)

Engine Number see page 86 (IDENTIFICATION

DATA)

Local aprilia Dealer Name

Local aprilia Dealer Address

Local aprilia Dealer Telephone Number

Warranty Activation Date

(from Retail Purchase Warranty Activation Form)

The following is to help you keep an accurate record of maintenance work.

Information recorded is not considered proof that maintenance has been carried out.

Keep copies of work orders and/or receipts for parts you purchase.

Date

Odometer

Maintenance Performed

Dealer Stamp

reading

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Follow X

use and maintenance TUONO 1000 USA 83

Date

Odometer

Maintenance Performed

Dealer Stamp

reading

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Follow X

84 use and maintenanceTUONO 1000 USA

Date

Odometer

Maintenance Performed

Dealer Stamp

reading

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

use and maintenance TUONO 1000 USA 85

1

2

IDENTIFICATION DATA

It is a good idea to write down the frame and engine numbers in the space provided below. Use the frame number (VIN) to identify your vehicle when ordering spare parts.

WARNING

In all states and countries, it is against the law to alter the Vehicle Identification Number (VIN). You can incur severe penalties by doing this. Also, this will immediately invalidate your warranty.

FRAME NUMBER

The frame number (A) is stamped on the right side of the fork head.

Frame no. _______________________

ENGINE NUMBER

The engine number (B) is stamped on the rear part of the left engine crankcase.

Engine no. _______________________

JOINTS WITH CLICK CLAMPS AND WITH SCREW-TYPECLAMPS

CAUTION

Remove ONLY the clamps indicated in the maintenance procedures. The following text does not authorize the arbitrary removal of the clamps present on the vehicle.

WARNING

Before removing a clamp, make sure that its oval does not cause any fluid leakage; if so, provide for preventing such leakage and protect the parts placed around the joint.

CLICK CLAMPS

For removal it is sufficient to use simple pliers, while for installation a special tool is required (see below).

Before removing a clamp, prepare the material necessary for the correct installation of the new clamp.

NOTE Have the appropriate special toolavailable:

- click clamp installation pliers, see page 46 (SPECIAL TOOLS).

CAUTION

Upon installation, replace the click clamp that has been removed with a new click clamp having the same dimensions, available from your Local aprilia Dealer.

Do not attempt to reinstall the removed click clamp, since it is unusable. Do not replace the removed click clamp with a screw-typeclamp or with other types of clamps.

CAUTION

Proceed with care, in order not to damage the joint components.

uWork with the pliers on the head of the click clamp, forcing until you release it.

SCREW-TYPECLAMPS

For removal and installation it is sufficient to use a simple screwdriver.

CAUTION

Check the conditions of the screw-typeclamp and if necessary replace it with a newscrew-typeclamp of the same dimensions, available from your Local aprilia Dealer.

When fastening the screw-typeclamp, make sure that the joint is sufficiently stable.

86 use and maintenanceTUONO 1000 USA

AIR CLEANER

 

 

C a r e f u l l y

r e a d

p a g e 7 9

(MAINTENANCE).

 

 

WARNING

Do not use gasoline or flammable solvents to wash the air cleaner, in order to avoid fire or explosion.

CAUTION

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

Inspect the air cleaner for clogging every 6,250 mi (1,000 km) or 12 months of use. Replace the air cleaner with a new one every 12,500 mi (20,000 km).

The air cleaner must be inspected more frequently, cleaned if necessary, and replaced more frequently if the vehicle is used on dusty or wet roads.

More frequent cleaning of the air cleaner is suggested, especially if your bike is used under very dusty conditions.

CAUTION

The air cleaner must not be used for more than 12,500 mi (20,000 km) regardless of how many times it has been cleaned in the interval. Under very dusty or dirty conditions, it is advisable to replace the air cleaner more often.

Before cleaning, it is necessary to remove the air cleaner from the vehicle.

1

KEEP POLLUTING SUBSTANCES AND C O M P O N E N T S A W A Y F R O M CHILDREN. DISPOSE OF POLLUTING SUBSTANCES AND COMPONENTS PROPERLY.

uEvery 6,250 mi (10,000 km) remove the plug (1) so that any dirt that may have accumulated inside the filter case can be removed and disposed properly.

2

2

2

2

2

2

2

REMOVAL

uLift the fuel tank, see page 108 [LIFTING THE FUEL TANK].

CAUTION

Before unscrewing and removing the screws (2), clean the filter case cover (3) and the filter case (4) with a clean cloth. Prevent any foreign matter from getting into the inlet tubes. This could cause severe engine damage.

uLift the fuel tank, see page 79 (LIFTING THE FUEL TANK).

uLoosen and remove the seven screws

(2).

uRemove the air box cover (3).

uLoosen and remove the two screws (4).

uRemove the air cleaner retaining bracket

(5).

uExtract the air cleaner (6).

uCheck the seal (7) for wear or damage and replace as required.

use and maintenance TUONO 1000 USA 87

3

4

5

7

6

CAUTION

Plug the opening with a clean cloth to prevent any foreign matter from entering the intake tubes.

When reassembling, before putting back the filter case cover (3), make sure that you have not left the cloth or other objects inside the case. Make sure that the air cleaner is positioned correctly, in such a way as to prevent non-filteredair from entering. Premature wear of the piston rings, pistons and cylinders is caused by an improperly installed air cleaner.

CLEANING

CAUTION

Take great care not to deform the perforated metal outside screen. It is very fragile and can be easily damaged. Never use a screwdriver or other sharp hard tool to remove the air cleaner itself.

WARNING

During this operation, always wear goggles which provide your eyes with 360° protection.

Be very careful using compressed air jets, they can cause serious personal injury if directed towards your body.

uGrasp the air cleaner (6) vertically and strike it repeatedly on a clean hard horizontal surface.

uIf available, clean the air cleaner (6) with a compressed air jet, directing it from the inside of the filter towards the outside.

CAUTION

When cleaning the air cleaner, make sure that there are no tears. If there are, replace the air cleaner element with a new one of the same type.

uClean the outer part of the air cleaner (6) with a cloth.

CHANGING

CAUTION

Never reuse an air cleaner.

uReplace the air cleaner (6) with a new one of the same type.

88 use and maintenanceTUONO 1000 USA

1

MPH

A

CHECKING THE ENGINE OIL LEVEL AND TOPPING UP

Carefully read page 48 (LUBRICANTS), page 79 (MAINTENANCE) and page 141 (LUBRICANT CHART).

WARNING

It is critical to the safe operation of your vehicle that the proper lubricants, maintained at the proper levels, are used. Failure to observe this warning can lead to engine seizure which can result in accidents, serious injury or death.

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

Periodically check the engine oil level, and change oil after the first 625 mi (1,000 km) and every 6,250 mi (10,000 km) thereafter, see page 65 (CHANGING ENGINE OIL AND THE ENGINE OIL FILTER).

CAUTION

If the vehicle is used for racing, change the engine oil every 3,125 mi (5,000 km). Change oil more frequently if the vehicle is used in dusty conditions.

CHECKING

NOTE Place the vehicle on firm and flat ground.

CAUTION

The engine oil level must be checked when the engine is warm.

If the check is carried out when the engine is cold, the oil level may temporarily lower below the “MIN” mark.

This is not a problem, provided that the engine oil pressure icon“ ” (A) does not come on, see page 32 (INSTRUMENT AND INDICATOR TABLE).

WARNING

Exhaust gases contain carbon monoxide, which is extremely poisonous if inhaled. Do not start the engine in closed or poorly-ventilatedrooms. Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.

uCheck the oil when the engine is warm, having been ridden for at least 10 mi (15 km).

NOTE If the engine is cold, warm it up for riding, preferably on a hilly road, for approximately 10 mi (15 km) before checking the oil.

2

3

u Stop the engine before checking the oil.

WARNING

Should your vehicle overturn, it will leak gasoline, which is extremely flammable. Flames or sparks may cause a fire, which could destroy not only the vehicle, but also the building in which it is located, and cause serious injuries or even death.

uKeep the vehicle vertical, with the two wheels resting on the ground.

NOTE If you attempt to check the oil with the vehicle in any position other than vertical, the measurement will be inaccurate.

NOTE If the engine oil tank is dirty, wipe it with a clean cloth so that the “MIN” and “MAX” marks are visible.

uLook through the appropriate slots (1) in the left fairing. Check the oil level in the inspection glass (2).

use and maintenance TUONO 1000 USA 89

DANGER

3

OF

 

BURNS

 

5

3

4

2

MAX = maximum level

MIN = minimum level

The difference between “MAX” and “MIN” is about 0.53 US qt (500 cm3).

uThe level is correct if the oil reaches approx. the “MAX” mark.

WARNING

Never exceed the “MAX” mark, nor leave the oil below the “MIN” mark, in order to avoid serious damage to the engine.

If necessary, top up the engine oil tank:

CAUTION

When warmed up, the engine contains hot oil and the engine oil tank (4) is warm; therefore, while carrying out the operations described here below, be particularly careful, in order to avoid burns.

CAUTION

Use thick gloves to prevent burns.

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

CAUTION

Before unscrewing and removing the filler cap (3), clean it and the area of the tank around it with a clean cloth. Prevent any foreign matter from falling into the oil tank, since this could cause serious engine damage.

Do not use any flammable solvents such as alcohol or gasoline when wiping the oil tank. The oil tank is hot enough to cause ignition of flammable solvents.

Use only a natural fiber cloth, e.g. cotton. Man made fabrics such as polyester, etc. could ignite.

u Unscrew and remove the filler cap (3).

CAUTION

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

WARNING

Do not add any additives or other substances to the engine oil.

If you use a funnel or other tool, make sure they are perfectly clean.

CAUTION

When topping up, never exceed the “MAX” level.

uTop up the engine oil tank (4) through the filler neck (5), with high-qualityengine oil, see page 141 (LUBRICANT CHART).

uReplace and tighten the filler cap (3).

WARNING

Tighten the filler cap (3) snugly to avoid leaks.

uReplace the left fairing, see page 109 [REMOVING THE SIDE FAIRINGS].

WARNING

Never ride your vehicle with low engine oil, or with contaminated oil, or with unapproved oil. Any of these will greatly accelerate wear of your engine, and cause irreparable damage.

90 use and maintenanceTUONO 1000 USA