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Aprilia Tuono R Factory 2006-Onwards Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Tuono R Factory Year: 2006 onwards Codes Engine Family Code: V60 Magnesium Chassis Code: Factory (specific designation may vary by year) 👋 Introduction Market Position Market Position: The Aprilia Tuono R Factory is a high-performance naked sportbike, renowned for its potent V-twin engine, advanced chassis, and aggressive styling. It targets experienced riders seeking exhilarating performance and a premium riding experience. Competitive Analysis Competitive Set: Competes with other premium naked sportbikes such as Ducati Monster series, KTM Super Duke, BMW S1000R, and Triumph Speed Triple of the same era. Key Features Key Features: Aprilia's renowned V60 Magnesium V-twin engine, advanced Öhlins suspension components (in Factory trim), high-performance braking system, lightweight chassis, and distinctive Italian design. 📋 Manual Details Coverage Areas Coverage: Complete Service, Repair, and Workshop procedures for the Aprilia Tuono R Factory (2006 onwards). Page Count Page Count: Estimated 400-600 pages (typical for comprehensive factory manuals of this era). Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine System: Complete engine overhaul, diagnostics, tuning, fuel injection, ignition, cooling, lubrication. Transmission System: Gearbox disassembly, assembly, maintenance, clutch operation and servicing. Chassis System: Frame, swingarm, steering head, wheel bearings, suspension (front forks and rear shock absorber) maintenance and adjustment. Brakes System: Brake system diagnostics, hydraulic system maintenance, pad replacement, caliper servicing, bleeding procedures. Electrical System: Wiring diagrams, component testing, battery, starter, alternator, lighting, ignition system troubleshooting. Fuel System: Fuel tank, fuel pump, fuel filter, injectors, ECU diagnostics. Exhaust System: Exhaust component inspection and replacement. Bodywork And Fairings: Panel removal, installation, and repair procedures. Instrumentation And Controls: Dashboard, switchgear, and control cable maintenance. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, spark plug service. Troubleshooting: Diagnostic flowcharts and common issue resolution for electrical and mechanical problems. Engine Rebuild: Detailed procedures for top-end and bottom-end engine rebuilds, including torque specifications and clearances. Suspension Adjustment And Rebuild: Fork oil changes, seal replacement, shock absorber servicing and adjustments. Electrical Diagnostics: Wiring diagram interpretation, component testing using multimeters, fault finding. Clutch And Transmission Service: Clutch plate replacement, gearbox component inspection and replacement, shift mechanism adjustments. Brake System Overhaul: Complete brake caliper servicing, master cylinder overhaul, and bleeding procedures. Wheel And Tire Service: Wheel bearing replacement, tire mounting and balancing, wheel alignment checks. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY enthusiasts. Covers everything from basic maintenance to full engine and chassis rebuilds. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution images and clear text, optimized for printing. Binding Type Binding Type: Not applicable (Digital Download PDF) Paper Type Paper Type: Not applicable (Digital Download PDF) Searchability Searchability: Text-searchable PDF for quick access to specific topics. Licensing Licensing: Unlimited access, no expiry dates as per product description. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, V90° longitudinally-mounted twin-cylinder engine (V60 Magnesium) Displacement: 997.6 cc (998cc) for early models, potentially 1078cc for later iterations depending on specific year interpretation of 'onwards'. Bore X Stroke: 98 x 66 mm (for 998cc) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approximately 130-140 HP (depending on specific year and configuration) Torque: Approximately 100-105 Nm (depending on specific year and configuration) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), likely Weber Marelli or similar, with twin injectors per cylinder. Fuel Type: Unleaded gasoline, minimum 95 RON (Octane rating) Ignition Ignition System: Digital electronic ignition with spark advance. Cooling System Cooling: Liquid-cooled Lubrication Oil Type: High-quality synthetic motorcycle oil, 10W-40 or 15W-50 typically recommended. Oil Capacity: Approximately 3.5 - 4.0 liters with filter change (refer to manual for exact specification). 🔧 Transmission Standard Transmission Type: 6-speed sequential manual gearbox Optional Optional Transmission: N/A (Manual gearbox is standard) Features Clutch Type: Hydraulically actuated, multi-plate wet clutch Final Drive: O-ring sealed chain drive 📐 Dimensions Exterior Length: Approx. 2095 mm (Varies slightly by year) Width: Approx. 800 mm (Varies slightly by year) Height: Approx. 1160 mm (Varies slightly by year) Wheelbase: Approx. 1440 mm Weights Dry Weight: Approx. 185 kg (Varies by year and specific Factory components) Curb Weight: Approx. 205-210 kg (fully fueled, ready to ride) Max Load: Refer to manual, typically around 200 kg including rider and luggage. 🛡️ Safety Features Ratings Safety Ratings: Motorcycles typically do not receive NHTSA or Euro NCAP ratings. Safety is inherent in design and rider skill. Active Features Brakes: High-performance radial-mount calipers (e.g., Brembo) with large diameter discs (front: dual 320mm, rear: single 220mm). ABS was optional or standard on later models. Lighting: Halogen headlights, LED taillight and indicators (depending on year). Passive Features Frame: Sturdy aluminium alloy frame designed for rigidity and feedback. Ergonomics: Sportbike-derived ergonomics with upright riding position, facilitating rider control. 💡 Technology Features Infotainment Infotainment System: Basic instrumentation...
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Aprilia Tuono R Factory 2006-Onwards Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Tuono R Factory
Year:
2006 onwards
Codes
Engine Family Code:
V60 Magnesium
Chassis Code:
Factory (specific designation may vary by year)
👋 Introduction
Market Position
Market Position:
The Aprilia Tuono R Factory is a high-performance naked sportbike, renowned for its potent V-twin engine, advanced chassis, and aggressive styling. It targets experienced riders seeking exhilarating performance and a premium riding experience.
Competitive Analysis
Competitive Set:
Competes with other premium naked sportbikes such as Ducati Monster series, KTM Super Duke, BMW S1000R, and Triumph Speed Triple of the same era.
Key Features
Key Features:
Aprilia's renowned V60 Magnesium V-twin engine, advanced Öhlins suspension components (in Factory trim), high-performance braking system, lightweight chassis, and distinctive Italian design.
📋 Manual Details
Coverage Areas
Coverage:
Complete Service, Repair, and Workshop procedures for the Aprilia Tuono R Factory (2006 onwards).
Page Count
Page Count:
Estimated 400-600 pages (typical for comprehensive factory manuals of this era).
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine System:
Complete engine overhaul, diagnostics, tuning, fuel injection, ignition, cooling, lubrication.
Transmission System:
Gearbox disassembly, assembly, maintenance, clutch operation and servicing.
Chassis System:
Frame, swingarm, steering head, wheel bearings, suspension (front forks and rear shock absorber) maintenance and adjustment.
Brakes System:
Brake system diagnostics, hydraulic system maintenance, pad replacement, caliper servicing, bleeding procedures.
Electrical System:
Wiring diagrams, component testing, battery, starter, alternator, lighting, ignition system troubleshooting.
Fuel System:
Fuel tank, fuel pump, fuel filter, injectors, ECU diagnostics.
Exhaust System:
Exhaust component inspection and replacement.
Bodywork And Fairings:
Panel removal, installation, and repair procedures.
Instrumentation And Controls:
Dashboard, switchgear, and control cable maintenance.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, spark plug service.
Troubleshooting:
Diagnostic flowcharts and common issue resolution for electrical and mechanical problems.
Engine Rebuild:
Detailed procedures for top-end and bottom-end engine rebuilds, including torque specifications and clearances.
Suspension Adjustment And Rebuild:
Fork oil changes, seal replacement, shock absorber servicing and adjustments.
Electrical Diagnostics:
Wiring diagram interpretation, component testing using multimeters, fault finding.
Clutch And Transmission Service:
Clutch plate replacement, gearbox component inspection and replacement, shift mechanism adjustments.
Brake System Overhaul:
Complete brake caliper servicing, master cylinder overhaul, and bleeding procedures.
Wheel And Tire Service:
Wheel bearing replacement, tire mounting and balancing, wheel alignment checks.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and experienced DIY enthusiasts. Covers everything from basic maintenance to full engine and chassis rebuilds.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution images and clear text, optimized for printing.
Binding Type
Binding Type:
Not applicable (Digital Download PDF)
Paper Type
Paper Type:
Not applicable (Digital Download PDF)
Searchability
Searchability:
Text-searchable PDF for quick access to specific topics.
Licensing
Licensing:
Unlimited access, no expiry dates as per product description.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, V90° longitudinally-mounted twin-cylinder engine (V60 Magnesium)
Displacement:
997.6 cc (998cc) for early models, potentially 1078cc for later iterations depending on specific year interpretation of 'onwards'.
Bore X Stroke:
98 x 66 mm (for 998cc)
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approximately 130-140 HP (depending on specific year and configuration)
Torque:
Approximately 100-105 Nm (depending on specific year and configuration)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), likely Weber Marelli or similar, with twin injectors per cylinder.
Fuel Type:
Unleaded gasoline, minimum 95 RON (Octane rating)
Ignition
Ignition System:
Digital electronic ignition with spark advance.
Cooling System
Cooling:
Liquid-cooled
Lubrication
Oil Type:
High-quality synthetic motorcycle oil, 10W-40 or 15W-50 typically recommended.
Oil Capacity:
Approximately 3.5 - 4.0 liters with filter change (refer to manual for exact specification).
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual gearbox
Optional
Optional Transmission:
N/A (Manual gearbox is standard)
Features
Clutch Type:
Hydraulically actuated, multi-plate wet clutch
Final Drive:
O-ring sealed chain drive
📐 Dimensions
Exterior
Length:
Approx. 2095 mm (Varies slightly by year)
Width:
Approx. 800 mm (Varies slightly by year)
Height:
Approx. 1160 mm (Varies slightly by year)
Wheelbase:
Approx. 1440 mm
Weights
Dry Weight:
Approx. 185 kg (Varies by year and specific Factory components)
Curb Weight:
Approx. 205-210 kg (fully fueled, ready to ride)
Max Load:
Refer to manual, typically around 200 kg including rider and luggage.
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles typically do not receive NHTSA or Euro NCAP ratings. Safety is inherent in design and rider skill.
Active Features
Brakes:
High-performance radial-mount calipers (e.g., Brembo) with large diameter discs (front: dual 320mm, rear: single 220mm). ABS was optional or standard on later models.
Lighting:
Halogen headlights, LED taillight and indicators (depending on year).
Passive Features
Frame:
Sturdy aluminium alloy frame designed for rigidity and feedback.
Ergonomics:
Sportbike-derived ergonomics with upright riding position, facilitating rider control.
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation typical for the era: Analog tachometer, digital speedometer, odometer, trip meters, clock, fuel gauge, engine warning lights.
Driver Assistance
ABS:
Optional or standard on later models within the '2006-onwards' range. The manual will detail its operation and servicing if equipped.
Connectivity
Connectivity:
N/A (No modern Bluetooth or smartphone integration on this model).
Engine Management
ECU:
Aprilia Performance Ride Control (APRC) system not present in this generation. Engine ECU controls fuel injection and ignition timing.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually, whichever comes first.
Valve Clearance Check:
Often at 10,000 - 15,000 km intervals, detailed in the manual.
Chain Maintenance:
Clean and lubricate every 500-1000 km, adjust tension as needed (refer to manual for slack specification).
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Refer to Aprilia specifications for correct type.
Brake Fluid Type:
DOT 4 or DOT 5.1 (check manual for precise recommendation), must be replaced periodically (e.g., every 2 years).
Clutch Fluid Type:
DOT 4 hydraulic fluid (same as brake fluid).
Fork Oil Type:
Specific viscosity grade (e.g., 5W or 10W), quantity and level are critical for performance.
Known Issues
Common Issues:
Potential for stator or rectifier failure, voltage regulator issues, occasional electrical gremlins (often wiring harness related), clutch slave cylinder leaks. Regular maintenance is key to mitigating these.
Maintenance Focus:
Proper maintenance of the V-twin engine, especially valve clearances and timely fluid changes, is crucial for longevity and optimal performance.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia has a strong heritage in motorcycle racing, particularly in Grand Prix, which influences the engineering and performance of its road-going models.
Model Evolution
Model Evolution Roots:
The Tuono line is derived from the RSV Mille sportbike, featuring a detuned engine and more upright ergonomics for street usability.
Factory Trim Enhancements:
The 'Factory' designation typically signifies higher-spec components, such as Öhlins suspension, forged wheels, and premium finishings compared to standard models.
Production
Production Period:
The second generation Tuono (based on the RSV1000R) ran from approximately 2006 to 2010, with the Factory variant being a premium offering within this period.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Consistently praised in contemporary reviews for its thrilling engine, sharp handling, and premium components. Often cited as one of the best-handling naked bikes of its time.
Industry Awards:
While specific awards for the '2006 Tuono R Factory' might not be individually cataloged, Aprilia models of this period frequently received accolades for engineering and performance from motorcycle publications.
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