APRILIA TUONO 1000 Service Repair Manual 2005 ONWARDS
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🏷️ Basic Information Identification Make: Aprilia Model: Tuono 1000 Year: 2005 onwards 👋 Introduction Market Position Segment: High-performance naked sportbike. Competitive Analysis Competitors: Ducati Monster, Triumph Speed Triple, Yamaha FZ1, Suzuki Bandit 1200/1250. Key Features Engine Architecture: V-twin engine, known for potent torque and aggressive power delivery. Handling Characteristics: Agile and responsive chassis, excellent for spirited riding and track days. Braking Performance: Typically equipped with high-quality braking components, offering strong stopping power. 📋 Manual Details Coverage Areas General Information: Included Lubrication: Included Inspection And Adjustment: Included Fuel System: Included Engine Servicing: Included Cylinder Head And Valve Servicing: Included Cylinder And Piston Servicing: Included Clutch Servicing: Included Gearshift Linkage Servicing: Included Sub Transmission Servicing: Included Crankcase Servicing: Included Transmission Servicing: Included Crankshaft And Primary Shaft Servicing: Included Front Wheel And Suspension Servicing: Included Rear Wheel And Suspension Servicing: Included Hydraulic Brake System Servicing: Included Battery And Charging System Servicing: Included Ignition System Servicing: Included Electric Starter Servicing: Included Switches Servicing: Included Troubleshooting: Included Page Count Estimated Page Count: Extensive (not specified but implied by content depth) Manual Type Type: Service Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Compatibility Pc Mac Compatible: Yes Features Zoom Functionality: Yes 📖 Manual Coverage Systems Covered Engine Mechanical: Complete rebuild, inspection, adjustment, lubrication, cylinder head, valves, pistons, crankshaft, primary shaft, crankcase. Fuel System: Components, diagnostics, and servicing of the fuel delivery system. Transmission And Drivetrain: Gearshift linkage, sub-transmission, main transmission, clutch, primary shaft operation. Suspension And Steering: Front and rear wheel and suspension systems, including inspection, adjustment, and repair. Braking System: Hydraulic brake system components, operation, and servicing. Electrical System: Battery, charging system, ignition system, electric starter, switches, and wiring diagrams. Bodywork And Chassis: Implied through general repair and disassembly/reassembly procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake fluid checks, spark plug replacement, lubrication points. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system servicing, electrical system diagnostics and repair. Diagnostics: Troubleshooting guides for various systems, identifying common problems and solutions. Rebuilding: Detailed step-by-step instructions for rebuilding major components like the engine and transmission. Wiring And Electrical: Comprehensive electrical diagrams for troubleshooting and re-wiring. Technical Depth Depth: Comprehensive workshop level. Covers from basic maintenance to full engine and component rebuilds, including electrical schematics. 📊 Manual Specifications File Format Searchable Text: Likely, as is standard for PDF service manuals. Print Quality Printable: Yes Binding Type Digital Format: N/A (Digital Download) Paper Type Digital Format: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin, Four-stroke Displacement: Approx. 998cc (depending on specific sub-model variations within '05 onwards) Bore X Stroke: Typically around 97 mm x 68 mm (requires specific model year confirmation from manual) Compression Ratio: Around 11.4:1 (typical for this era's models) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Est. 120-130 HP (varies by model year and tuning) Torque: Est. 70-75 lb-ft (varies by model year and tuning) Fuel System Fuel Delivery: Fuel Injection (Electronic) Fuel Type: Unleaded Gasoline, Octane Rating 95 (RON) Lubrication Oil Type: API SG or higher, JASO MA certified motorcycle oil, SAE 10W-40 recommended (specifics in manual). Oil Capacity: Approx. 3.7 - 4.0 liters with filter change (exact value in manual). 🔧 Transmission Standard Type: 6-speed, constant mesh Features Clutch Type: Hydraulically operated, wet multi-plate Final Drive: O-ring sealed chain 📐 Dimensions Exterior Wheelbase: Approx. 1415 mm (55.7 inches) (varies slightly by model year) Weights Dry Weight: Approx. 185-195 kg (408-430 lbs) (varies by model year and equipment) Wet Weight: Approx. 205-215 kg (452-474 lbs) (varies by model year and fluids) 🛡️ Safety Features Active Features Brakes: Dual front discs with radial-mount calipers, single rear disc. ABS available on some models. Suspension: Fully adjustable upside-down front forks and adjustable rear monoshock absorber for customizable handling and stability. 💡 Technology Features Infotainment Features: Basic analogue/digital instrumentation cluster; no integrated infotainment or connectivity in the modern sense. Driver Assistance ABS: Optional on some models, providing enhanced braking safety. Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change: Every 5,000 - 6,000 km or annually (refer to manual for exact interval and oil type). Valve Clearance Check: Typically around 10,000 - 12,000 km (critical for V-twin engine health, consult manual). Chain Lubrication And Adjustment: Every 500-1,000 km, and adjustment as needed based on slack. Coolant Flush: Every 2 years or specified mileage (refer to manual). Fluid Specifications Brake Fluid: DOT 4 (refer to manual for exact specification and type). Coolant: Ethylene glycol-based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water. Known Issues Electrical Connections: Some owners report occasional issues with electrical connectors due to vibration or moisture ingress, requiring inspection and dielectric grease. Clutch Slave Cylinder: Can sometimes develop leaks, requiring replacement of seals or the unit. Fuel Pump Relay: Occasional reports of fuel pump relay failure, leading...
Engine rebuilds, transmission overhauls, suspension component replacement, brake system servicing, electrical system diagnostics and repair.
Diagnostics:
Troubleshooting guides for various systems, identifying common problems and solutions.
Rebuilding:
Detailed step-by-step instructions for rebuilding major components like the engine and transmission.
Wiring And Electrical:
Comprehensive electrical diagrams for troubleshooting and re-wiring.
Technical Depth
Depth:
Comprehensive workshop level. Covers from basic maintenance to full engine and component rebuilds, including electrical schematics.
📊 Manual Specifications
File Format
Searchable Text:
Likely, as is standard for PDF service manuals.
Print Quality
Printable:
Yes
Binding Type
Digital Format:
N/A (Digital Download)
Paper Type
Digital Format:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-stroke
Displacement:
Approx. 998cc (depending on specific sub-model variations within '05 onwards)
Bore X Stroke:
Typically around 97 mm x 68 mm (requires specific model year confirmation from manual)
Compression Ratio:
Around 11.4:1 (typical for this era's models)
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Est. 120-130 HP (varies by model year and tuning)
Torque:
Est. 70-75 lb-ft (varies by model year and tuning)
Fuel System
Fuel Delivery:
Fuel Injection (Electronic)
Fuel Type:
Unleaded Gasoline, Octane Rating 95 (RON)
Lubrication
Oil Type:
API SG or higher, JASO MA certified motorcycle oil, SAE 10W-40 recommended (specifics in manual).
Oil Capacity:
Approx. 3.7 - 4.0 liters with filter change (exact value in manual).
🔧 Transmission
Standard
Type:
6-speed, constant mesh
Features
Clutch Type:
Hydraulically operated, wet multi-plate
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Wheelbase:
Approx. 1415 mm (55.7 inches) (varies slightly by model year)
Weights
Dry Weight:
Approx. 185-195 kg (408-430 lbs) (varies by model year and equipment)
Wet Weight:
Approx. 205-215 kg (452-474 lbs) (varies by model year and fluids)
🛡️ Safety Features
Active Features
Brakes:
Dual front discs with radial-mount calipers, single rear disc. ABS available on some models.
Suspension:
Fully adjustable upside-down front forks and adjustable rear monoshock absorber for customizable handling and stability.
💡 Technology Features
Infotainment
Features:
Basic analogue/digital instrumentation cluster; no integrated infotainment or connectivity in the modern sense.
Driver Assistance
ABS:
Optional on some models, providing enhanced braking safety.
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 6,000 km or annually (refer to manual for exact interval and oil type).
Valve Clearance Check:
Typically around 10,000 - 12,000 km (critical for V-twin engine health, consult manual).
Chain Lubrication And Adjustment:
Every 500-1,000 km, and adjustment as needed based on slack.
Coolant Flush:
Every 2 years or specified mileage (refer to manual).
Fluid Specifications
Brake Fluid:
DOT 4 (refer to manual for exact specification and type).
Coolant:
Ethylene glycol-based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water.
Known Issues
Electrical Connections:
Some owners report occasional issues with electrical connectors due to vibration or moisture ingress, requiring inspection and dielectric grease.
Clutch Slave Cylinder:
Can sometimes develop leaks, requiring replacement of seals or the unit.
Fuel Pump Relay:
Occasional reports of fuel pump relay failure, leading to starting issues.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its performance motorcycles, particularly in racing and sportbike segments.
Model Evolution
Tuono Lineage:
The Tuono is the naked sportbike variant derived from the Aprilia RSV Mille sportbike, offering a more upright riding position and aggressive styling.
Production
Era:
The 2005 onwards designation covers a significant period of evolution for the Tuono 1000, including the SL1000 (V-twin) platform.
🏆 Awards & Recognition
Recognitions
Performance Acclaim:
The Tuono has historically been praised for its potent engine and sharp handling, often reviewed positively for its visceral riding experience and value proposition compared to some European counterparts.