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Aprilia Tuono 1000 Motorcycle Complete Workshop Service Repair Manual 2006 2007 2008 2009

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🏷️ Basic Information Identification Make: Aprilia Model: Tuono 1000 Model Variant: R / Factory (implied by general workshop manual coverage) Engine Type: V-Twin, Four-Stroke Generation Generation Identifier: Second Generation (Facelifted/Revised from original Tuono) Codes Chassis Code: RP (common for Tuono 1000 R) 👋 Introduction Market Position Category: High-performance naked sportbike Target Audience: Enthusiast riders seeking maximum performance and engaging riding experience, requiring detailed service information. Competitive Analysis Competitors: Ducati Monster, Triumph Speed Triple, Yamaha FZ1, Suzuki GSX-S1000 (later models). Key Features Engine Performance: Powerful V-Twin engine derived from the RSV Mille superbike, offering strong torque and exhilarating acceleration. Handling Chassis: Stiff aluminum frame, sophisticated suspension (often Öhlins on Factory models), and powerful Brembo brakes provide exceptional handling and feedback. Design Ergonomics: Naked styling with aggressive ergonomics, comfortable for spirited riding and everyday use compared to its faired sibling. Value Proposition Manual Value: Essential for owners to maintain the performance and longevity of this high-strung Italian motorcycle. 📋 Manual Details Coverage Areas Engine: Comprehensive Transmission: Comprehensive Chassis: Comprehensive Electrical System: Comprehensive Bodywork And Trim: Comprehensive Suspension: Comprehensive Brakes: Comprehensive Fuel System: Comprehensive Cooling System: Comprehensive Exhaust System: Comprehensive Wheels And Tires: Comprehensive Troubleshooting: Comprehensive Maintenance Schedules: Comprehensive Page Count Estimated Pages: 500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, inspection, rebuild procedures for V60 Rotax engine (1000cc). Engine Management: Fuel injection system (Weber Marelli), ignition system, sensors, ECU diagnostics, and component testing. Transmission Drivetrain: Clutch operation and replacement, gearbox disassembly, inspection, and reassembly, final drive chain and sprockets. Braking System: Brake fluid replacement, caliper service, master cylinder overhaul, disc inspection, ABS system (if equipped). Suspension Steering: Front fork (Showa/Öhlins depending on variant) disassembly, service, and adjustment; rear shock absorber service; steering head bearing maintenance. Electrical Lighting: Wiring diagrams, starter system, charging system (stator, regulator/rectifier), lighting circuits, battery maintenance, dashboard and instrument cluster diagnostics. Cooling System: Radiator service, fan operation, coolant replacement, thermostat testing, water pump maintenance. Exhaust System: Catalytic converter inspection, muffler service, exhaust pipe sealing. Fuel System: Fuel tank removal/installation, fuel pump operation, fuel filter replacement, fuel line inspection. Bodywork Faring: Fairing panel removal and installation, seat service, luggage options (if applicable). Procedures Included Routine Maintenance: Oil and filter changes, spark plug replacement, air filter service, chain lubrication and adjustment, brake pad inspection. Troubleshooting Diagnostics: Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation. Major Engine Repairs: Top-end rebuilds (cylinder heads, valves), bottom-end rebuilds (crankshaft, connecting rods, pistons), timing system service. Transmission Overhaul: Complete gearbox rebuild, including gear selection mechanism and clutch components. Electrical Component Replacement: Alternator stator replacement, regulator/rectifier replacement, starter motor service, battery replacement procedure. Suspension Tuning: Front fork internal service, rear shock adjustment procedures, steering damper setup (if applicable). Brake System Overhaul: Full brake system bleeding, caliper piston service, master cylinder seal replacement. Wiring Diagram Interpretation: Detailed wiring schematics for all electrical systems. Wheel Bearing Service: Front and rear wheel bearing replacement. Torque Specifications: Comprehensive list of all critical torque values for fasteners. Technical Depth Depth: Complete workshop level, covering routine maintenance to full engine and component rebuilds. Diagnostic Capability: Detailed diagnostic trees and procedures for electrical and mechanical faults. Special Tools: Identification and usage of specialized tools required for certain procedures. 📊 Manual Specifications File Format Format: PDF Searchability: Fully searchable text content Resolution: High-resolution, suitable for printing Print Quality Printability: Printable pages Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: V60 Rotax Displacement: 997.6 cc Bore X Stroke: 97 mm x 68 mm Configuration: Longitudinal V-Twin, 60-degree cylinder angle Valve Train: DOHC, 4 valves per cylinder, chain-driven cams Cooling System: Liquid-cooled Compression Ratio: 11.3:1 Performance Horsepower: Approx. 130 hp @ 9,500 rpm Torque: Approx. 70 lb-ft @ 7,200 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (Weber Marelli) with dual injectors per cylinder Fuel Type: Unleaded gasoline, 95-98 RON Ignition System: Electronic ignition, twin spark plugs per cylinder 🔧 Transmission Standard Type: 6-speed manual transmission Clutch Type: Wet, multi-plate, hydraulically operated Final Drive: Chain drive Features Gear Ratios: Specific ratios provided in manual Clutch Fluid Spec: DOT 4 brake fluid Transmission Oil Capacity: Approx. 1.5 liters (check manual for exact spec) Transmission Oil Type: SAE 10W-50 or SAE 15W-50, API SG/SH/SJ or higher, JASO MA/MA2 certified motorcycle oil 📐 Dimensions Exterior Length: Approx. 2,060 mm Width: Approx. 790 mm Height: Approx. 1,120 mm Wheelbase: Approx. 1,410 mm Weights Dry Weight: Approx. 190 kg Wet Weight: Approx. 215 kg (with fluids) Fuel Tank Capacity: 18 liters 🛡️ Safety Features Ratings ABS: Optional on some models/markets Active Features Braking System: Radial-mount Brembo calipers, dual 320mm front discs, 220mm rear disc. Suspension Adjustment: Adjustable front forks and rear shock for rider preference and conditions. Passive Features...
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SKU: 530684
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Aprilia Tuono 1000 Motorcycle Complete Workshop Service Repair Manual 2006 2007 2008 2009
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Tuono 1000
Model Variant:
R / Factory (implied by general workshop manual coverage)
Engine Type:
V-Twin, Four-Stroke
Generation
Generation Identifier:
Second Generation (Facelifted/Revised from original Tuono)
Codes
Chassis Code:
RP (common for Tuono 1000 R)
👋 Introduction
Market Position
Category:
High-performance naked sportbike
Target Audience:
Enthusiast riders seeking maximum performance and engaging riding experience, requiring detailed service information.
Competitive Analysis
Competitors:
Ducati Monster, Triumph Speed Triple, Yamaha FZ1, Suzuki GSX-S1000 (later models).
Key Features
Engine Performance:
Powerful V-Twin engine derived from the RSV Mille superbike, offering strong torque and exhilarating acceleration.
Handling Chassis:
Stiff aluminum frame, sophisticated suspension (often Öhlins on Factory models), and powerful Brembo brakes provide exceptional handling and feedback.
Design Ergonomics:
Naked styling with aggressive ergonomics, comfortable for spirited riding and everyday use compared to its faired sibling.
Value Proposition
Manual Value:
Essential for owners to maintain the performance and longevity of this high-strung Italian motorcycle.
📋 Manual Details
Coverage Areas
Engine:
Comprehensive
Transmission:
Comprehensive
Chassis:
Comprehensive
Electrical System:
Comprehensive
Bodywork And Trim:
Comprehensive
Suspension:
Comprehensive
Brakes:
Comprehensive
Fuel System:
Comprehensive
Cooling System:
Comprehensive
Exhaust System:
Comprehensive
Wheels And Tires:
Comprehensive
Troubleshooting:
Comprehensive
Maintenance Schedules:
Comprehensive
Page Count
Estimated Pages:
500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine disassembly, inspection, rebuild procedures for V60 Rotax engine (1000cc).
Engine Management:
Fuel injection system (Weber Marelli), ignition system, sensors, ECU diagnostics, and component testing.
Transmission Drivetrain:
Clutch operation and replacement, gearbox disassembly, inspection, and reassembly, final drive chain and sprockets.
Braking System:
Brake fluid replacement, caliper service, master cylinder overhaul, disc inspection, ABS system (if equipped).
Suspension Steering:
Front fork (Showa/Öhlins depending on variant) disassembly, service, and adjustment; rear shock absorber service; steering head bearing maintenance.
Electrical Lighting:
Wiring diagrams, starter system, charging system (stator, regulator/rectifier), lighting circuits, battery maintenance, dashboard and instrument cluster diagnostics.
Cooling System:
Radiator service, fan operation, coolant replacement, thermostat testing, water pump maintenance.
Exhaust System:
Catalytic converter inspection, muffler service, exhaust pipe sealing.
Fuel System:
Fuel tank removal/installation, fuel pump operation, fuel filter replacement, fuel line inspection.
Bodywork Faring:
Fairing panel removal and installation, seat service, luggage options (if applicable).
Procedures Included
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter service, chain lubrication and adjustment, brake pad inspection.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation.
Major Engine Repairs:
Top-end rebuilds (cylinder heads, valves), bottom-end rebuilds (crankshaft, connecting rods, pistons), timing system service.
Transmission Overhaul:
Complete gearbox rebuild, including gear selection mechanism and clutch components.
Electrical Component Replacement:
Alternator stator replacement, regulator/rectifier replacement, starter motor service, battery replacement procedure.
Suspension Tuning:
Front fork internal service, rear shock adjustment procedures, steering damper setup (if applicable).
Brake System Overhaul:
Full brake system bleeding, caliper piston service, master cylinder seal replacement.
Wiring Diagram Interpretation:
Detailed wiring schematics for all electrical systems.
Wheel Bearing Service:
Front and rear wheel bearing replacement.
Torque Specifications:
Comprehensive list of all critical torque values for fasteners.
Technical Depth
Depth:
Complete workshop level, covering routine maintenance to full engine and component rebuilds.
Diagnostic Capability:
Detailed diagnostic trees and procedures for electrical and mechanical faults.
Special Tools:
Identification and usage of specialized tools required for certain procedures.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Fully searchable text content
Resolution:
High-resolution, suitable for printing
Print Quality
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
V60 Rotax
Displacement:
997.6 cc
Bore X Stroke:
97 mm x 68 mm
Configuration:
Longitudinal V-Twin, 60-degree cylinder angle
Valve Train:
DOHC, 4 valves per cylinder, chain-driven cams
Cooling System:
Liquid-cooled
Compression Ratio:
11.3:1
Performance
Horsepower:
Approx. 130 hp @ 9,500 rpm
Torque:
Approx. 70 lb-ft @ 7,200 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Weber Marelli) with dual injectors per cylinder
Fuel Type:
Unleaded gasoline, 95-98 RON
Ignition System:
Electronic ignition, twin spark plugs per cylinder
🔧 Transmission
Standard
Type:
6-speed manual transmission
Clutch Type:
Wet, multi-plate, hydraulically operated
Final Drive:
Chain drive
Features
Gear Ratios:
Specific ratios provided in manual
Clutch Fluid Spec:
DOT 4 brake fluid
Transmission Oil Capacity:
Approx. 1.5 liters (check manual for exact spec)
Transmission Oil Type:
SAE 10W-50 or SAE 15W-50, API SG/SH/SJ or higher, JASO MA/MA2 certified motorcycle oil
📐 Dimensions
Exterior
Length:
Approx. 2,060 mm
Width:
Approx. 790 mm
Height:
Approx. 1,120 mm
Wheelbase:
Approx. 1,410 mm
Weights
Dry Weight:
Approx. 190 kg
Wet Weight:
Approx. 215 kg (with fluids)
Fuel Tank Capacity:
18 liters
🛡️ Safety Features
Ratings
ABS:
Optional on some models/markets
Active Features
Braking System:
Radial-mount Brembo calipers, dual 320mm front discs, 220mm rear disc.
Suspension Adjustment:
Adjustable front forks and rear shock for rider preference and conditions.
Passive Features
Frame Construction:
Lightweight aluminum alloy twin-spar frame for rigidity and handling.
Lighting:
Halogen headlights, LED taillight.
💡 Technology Features
Infotainment
Dashboard:
Digital and analog instrument cluster displaying speed, RPM, odometer, trip meters, fuel level, coolant temperature, and warning lights.
Engine Management System:
Weber Marelli electronic fuel injection and ignition system.
Driver Assistance
ABS:
Available as an optional feature on certain models for enhanced braking control.
Connectivity
Diagnostic Ports:
On-board diagnostic connector for ECU access and fault code retrieval.
🔧 Maintenance
Service Intervals
Oil Filter Change:
Every 7,500 km or 12 months
Engine Oil Change:
Every 7,500 km or 12 months (using correct grade oil)
Spark Plug Replacement:
Every 15,000 km
Air Filter Cleaning:
Every 7,500 km, replace as needed
Chain Lubrication Adjustment:
Every 1,000 km or as needed based on conditions
Valve Clearance Check:
Every 15,000 km
Fluid Specifications
Engine Oil:
SAE 10W-50 or SAE 15W-50, API SG/SH/SJ or higher, JASO MA/MA2
Coolant:
Mixture of ethylene glycol-based antifreeze and distilled water (50/50 ratio)
Brake Fluid:
DOT 4
Fork Oil:
Specific viscosity and level as per manual (e.g., 5W or 7.5W)
Known Issues
Electrical Connections:
Can be prone to corrosion if not maintained, especially around the main harness connectors.
Fuel Pump:
Occasional issues reported, maintenance of the fuel filter is crucial.
Stator Failure:
Can occur with age/mileage, requiring replacement of the stator and potentially the regulator/rectifier.
Regulator Rectifier Overheating:
Can overheat and fail, often exacerbated by poor airflow or a failing stator.
Clutch Slave Cylinder Leaks:
Can develop leaks over time, requiring seal replacement.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Brand Focus:
Performance motorcycles, racing heritage.
Model Evolution
Genesis:
Evolved from the RSV Mille sportbike, re-tuned for street performance and naked styling.
Updates For 2006-2009:
Refined engine mapping, chassis tweaks, updated styling, potential for different suspension components (e.g., Öhlins on Factory models).
Production
Production Years:
2001-2013 (Tuono 1000 platform)
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Press:
Consistently praised by motorcycle journalists for its performance, handling, and character.
Rider Reviews:
Highly regarded by owners for its engaging riding experience and potent V-twin engine.
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