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Aprilia Tuono V990 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Tuono V990 Year: 2004 Model Variant: Factory Codes Chassis Code: RP Engine Code: Rotax V990 👋 Introduction Market Position Vehicle Segment: High-performance naked sportbike Target Owner: Enthusiast seeking performance and handling with a focus on mechanical understanding and DIY maintenance Competitive Analysis Competitors 2004: Ducati Monster S4, Triumph Speed Triple, KTM 950 Supermoto Key Features Unique Selling Points Vehicle: V-twin engine character, sharp handling, Italian styling Unique Selling Points Manual: Genuine Factory content, comprehensive coverage, digital format for ease of use and printing Value Proposition Cost Savings: Potential savings of $50-$60 per hour on labor costs by performing servicing yourself 📋 Manual Details Coverage Areas Primary Coverage: Full Factory Service Repair Secondary Coverage: Maintenance, Diagnostics, Troubleshooting, Repair, Rebuild, Restoration Applicable Styles: All Styles Covered Page Count Estimated Pages: Hundreds Manual Type Type: Factory Service Repair Manual Origin: Genuine Factory Manuals (Not 3rd Party) Language Language: English Format File Format: PDF Delivery Method: Digital Download 📖 Manual Coverage Systems Covered Engine Systems: Engine Identification, Engine Body, Fuel System, Cooling System, Fuel Filter, Alternator, Regulator Electrical Systems: Electrical System, Wiring Diagrams Chassis Systems: General Precautions, Maintenance Check List, Check and Maintenance, Special Tools, Disassembling and Servicing Procedures Included Maintenance Procedures: Scheduled Maintenance, Fluid Checks and Replacements, Filter Replacements Repair Procedures: Step-by-step repair instructions for all covered systems Diagnostic Procedures: Advanced troubleshooting guide, problem diagnosis and correction Tuning Procedures: Tuning related information Technical Depth Depth: Comprehensive (Fundamentals to Rebuild) Target Audience: Owner, DIY Mechanic, Professional Technician Knowledge Transfer: Teaches what factory-trained technicians know 📊 Manual Specifications File Format File Type: PDF Readability Software: Adobe PDF Reader Platform Compatibility: Windows, macOS Print Quality Printability: Fully Printable (All pages or selected pages) Resolution: High Resolution Binding Type Binding: N/A (Digital Download - Print as needed) Paper Type Paper Type: N/A (Digital Download - Print on desired paper) Searchability Search Function: Yes (Enabled by PDF format) Usability Navigation: Numbered table of contents, search function ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin, Four-stroke Displacement: 998 cc (60.9 cu in) Bore X Stroke: 97 mm x 68 mm Valvetrain: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower Claimed: 130 hp (96 kW) @ 9,500 rpm Torque Claimed: 99 Nm (73 lb-ft) @ 7,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (Weber Marelli) Fuel Type: Unleaded Petrol (95 RON recommended) Fuel Tank Capacity: 18 Liters (4.75 US gal) 🔧 Transmission Standard Transmission Type: 6-speed manual Features Clutch Type: Hydraulic, Wet multi-plate Final Drive: Chain 📐 Dimensions Exterior Length: 2100 mm (82.7 in) Width: 770 mm (30.3 in) Height: 1150 mm (45.3 in) Wheelbase: 1410 mm (55.5 in) Weights Dry Weight: 188 kg (414.5 lbs) Wet Weight: 205 kg (452 lbs) (approx.) 🛡️ Safety Features Ratings Safety Certification: TÜV, EC Homologation Active Features Braking System: Dual 320mm discs, 4-piston calipers (front); Single 220mm disc, 2-piston caliper (rear) Suspension Front: 43mm Marzocchi upside-down forks, fully adjustable Suspension Rear: Sachs monoshock, adjustable preload and rebound damping Passive Features Lighting: Dual Halogen Headlights, LED Taillight 💡 Technology Features Infotainment Dashboard: Analog tachometer, digital speedometer, LCD multi-function display (odo, trip, clock, etc.) Instrumentation: Warning lights for oil pressure, neutral, high beam, turn signals, etc. Driver Assistance ABS: Not standard on this model 🔧 Maintenance Service Intervals Oil Change Interval: 10,000 km (6,000 miles) or 12 months Valve Clearance Check: 20,000 km (12,000 miles) Fluid Specifications Engine Oil Type: SAE 10W-40, API SG/SH/SJ, JASO MA Coolant Type: Ethylene Glycol based coolant, 50% mixture with distilled water Brake Fluid Type: DOT 4 Clutch Fluid Type: DOT 4 (Hydraulic Clutch) Known Issues Common Problems: Regulator/Rectifier failures, occasional electrical gremlins, clutch slave cylinder leaks, fuel pump issues Maintenance Tips: Regular cleaning and lubrication of chain, periodic inspection of all hoses and connections, ensuring proper battery maintenance 📚 Vehicle History Brand Heritage Manufacturer Origin: Italy Brand Focus: Performance motorcycles, racing pedigree Model Evolution Tuono V990 Predecessor: Aprilia RSV Mille (Tuono is the naked version) Tuono V990 Development: Derived from the RSV Mille sportbike, adapted for street riding with revised ergonomics and styling Production Production Years: 2002-2005 (for the first generation V990 Tuono) 🏆 Awards & Recognition Recognitions Motorcycle Press Reviews: Praised for its potent engine, agile handling, and aggressive styling. Often cited as a raw and exciting riding experience. Ratings Customer Satisfaction: Generally high among owners who appreciate its performance and character, despite potential maintenance needs.
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Aprilia Tuono V990 2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Tuono V990
Year:
2004
Model Variant:
Factory
Codes
Chassis Code:
RP
Engine Code:
Rotax V990
👋 Introduction
Market Position
Vehicle Segment:
High-performance naked sportbike
Target Owner:
Enthusiast seeking performance and handling with a focus on mechanical understanding and DIY maintenance
Competitive Analysis
Competitors 2004:
Ducati Monster S4, Triumph Speed Triple, KTM 950 Supermoto
Key Features
Unique Selling Points Vehicle:
V-twin engine character, sharp handling, Italian styling
Unique Selling Points Manual:
Genuine Factory content, comprehensive coverage, digital format for ease of use and printing
Value Proposition
Cost Savings:
Potential savings of $50-$60 per hour on labor costs by performing servicing yourself
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Factory Service Repair
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Repair, Rebuild, Restoration
Applicable Styles:
All Styles Covered
Page Count
Estimated Pages:
Hundreds
Manual Type
Type:
Factory Service Repair Manual
Origin:
Genuine Factory Manuals (Not 3rd Party)
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Digital Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine Identification, Engine Body, Fuel System, Cooling System, Fuel Filter, Alternator, Regulator
Electrical Systems:
Electrical System, Wiring Diagrams
Chassis Systems:
General Precautions, Maintenance Check List, Check and Maintenance, Special Tools, Disassembling and Servicing
Procedures Included
Maintenance Procedures:
Scheduled Maintenance, Fluid Checks and Replacements, Filter Replacements
Repair Procedures:
Step-by-step repair instructions for all covered systems
Diagnostic Procedures:
Advanced troubleshooting guide, problem diagnosis and correction
Tuning Procedures:
Tuning related information
Technical Depth
Depth:
Comprehensive (Fundamentals to Rebuild)
Target Audience:
Owner, DIY Mechanic, Professional Technician
Knowledge Transfer:
Teaches what factory-trained technicians know
📊 Manual Specifications
File Format
File Type:
PDF
Readability Software:
Adobe PDF Reader
Platform Compatibility:
Windows, macOS
Print Quality
Printability:
Fully Printable (All pages or selected pages)
Resolution:
High Resolution
Binding Type
Binding:
N/A (Digital Download - Print as needed)
Paper Type
Paper Type:
N/A (Digital Download - Print on desired paper)
Searchability
Search Function:
Yes (Enabled by PDF format)
Usability
Navigation:
Numbered table of contents, search function
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-stroke
Displacement:
998 cc (60.9 cu in)
Bore X Stroke:
97 mm x 68 mm
Valvetrain:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower Claimed:
130 hp (96 kW) @ 9,500 rpm
Torque Claimed:
99 Nm (73 lb-ft) @ 7,500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Weber Marelli)
Fuel Type:
Unleaded Petrol (95 RON recommended)
Fuel Tank Capacity:
18 Liters (4.75 US gal)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Features
Clutch Type:
Hydraulic, Wet multi-plate
Final Drive:
Chain
📐 Dimensions
Exterior
Length:
2100 mm (82.7 in)
Width:
770 mm (30.3 in)
Height:
1150 mm (45.3 in)
Wheelbase:
1410 mm (55.5 in)
Weights
Dry Weight:
188 kg (414.5 lbs)
Wet Weight:
205 kg (452 lbs) (approx.)
🛡️ Safety Features
Ratings
Safety Certification:
TÜV, EC Homologation
Active Features
Braking System:
Dual 320mm discs, 4-piston calipers (front); Single 220mm disc, 2-piston caliper (rear)
Suspension Front:
43mm Marzocchi upside-down forks, fully adjustable
Suspension Rear:
Sachs monoshock, adjustable preload and rebound damping
Passive Features
Lighting:
Dual Halogen Headlights, LED Taillight
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, digital speedometer, LCD multi-function display (odo, trip, clock, etc.)
Instrumentation:
Warning lights for oil pressure, neutral, high beam, turn signals, etc.
Driver Assistance
ABS:
Not standard on this model
🔧 Maintenance
Service Intervals
Oil Change Interval:
10,000 km (6,000 miles) or 12 months
Valve Clearance Check:
20,000 km (12,000 miles)
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG/SH/SJ, JASO MA
Coolant Type:
Ethylene Glycol based coolant, 50% mixture with distilled water
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (Hydraulic Clutch)
Known Issues
Common Problems:
Regulator/Rectifier failures, occasional electrical gremlins, clutch slave cylinder leaks, fuel pump issues
Maintenance Tips:
Regular cleaning and lubrication of chain, periodic inspection of all hoses and connections, ensuring proper battery maintenance
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Brand Focus:
Performance motorcycles, racing pedigree
Model Evolution
Tuono V990 Predecessor:
Aprilia RSV Mille (Tuono is the naked version)
Tuono V990 Development:
Derived from the RSV Mille sportbike, adapted for street riding with revised ergonomics and styling
Production
Production Years:
2002-2005 (for the first generation V990 Tuono)
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Praised for its potent engine, agile handling, and aggressive styling. Often cited as a raw and exciting riding experience.
Ratings
Customer Satisfaction:
Generally high among owners who appreciate its performance and character, despite potential maintenance needs.
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