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Aprilia Tuono V990 2002 2003 2004 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: Tuono V990 Model Variant: V990 Generation Generation: First Generation Codes Platform Code: RSV-based (shared with RSV Mille) 👋 Introduction Market Position Market Segment: High-performance naked sportbike, competing with Ducati Monster, Triumph Speed Triple. Competitive Analysis Key Selling Points: Powerful V-twin engine, agile handling, aggressive styling, Italian engineering. Key Features Manual Utility: Essential resource for owners and mechanics for maintenance, repair, and troubleshooting, emphasizing clarity and detail. 📋 Manual Details Coverage Areas Years Covered: 2002, 2003, 2004, 2005 Page Count Page Count: 186 Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, diagnosis, testing, lubrication, cooling, fuel injection, ignition, exhaust. Drivetrain Systems: Clutch, gearbox (transmission), final drive (chain and sprockets). Chassis Systems: Frame, suspension (front forks, rear shock absorber), steering, wheels, tires. Braking Systems: Brake system diagnosis, hydraulic components, brake fluid, caliper, master cylinder, brake lines. Electrical Systems: Wiring diagrams, battery, charging system, lighting, ignition system, ECU, sensors, starter motor. Bodywork And Fixtures: Fairings, seat, fuel tank, instrumentation, fasteners. Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, chain adjustment, brake checks. Repair Procedures: Detailed step-by-step instructions for disassembly, assembly, and repair of all major components. Troubleshooting Guides: Diagnostic procedures for identifying and resolving common and uncommon issues. Adjustment Procedures: Carburetor/throttle body synchronization, valve clearance adjustment, suspension setup, electrical component adjustments. Special Tool Usage: Identification and usage instructions for specific Aprilia service tools. Technical Depth Depth Of Coverage: Comprehensive, from basic checks and maintenance to complete engine and transmission rebuilds, including diagnostic procedures. 📊 Manual Specifications File Format PDF Quality: High-resolution, viewable on any computer, zoomable. Print Quality Printability: All pages are printable. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Software Requirements Software Requirement: Adobe Reader (or compatible PDF viewer) Compatibility Operating Systems: Windows, Mac, Linux OS ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, four-stroke, liquid-cooled, DOHC, 8 valves Engine Displacement: 998 cc (997.6 cc) Bore X Stroke: 97 mm x 67.5 mm Performance Horsepower Approx: 120 - 130 HP (claimed, depending on specific model year/tune) Torque Approx: 95 - 100 Nm (claimed, depending on specific model year/tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Weber Marelli or similar Fuel Type: Unleaded gasoline, minimum 95 RON Lubrication Oil Type: SAE 10W-40 or 15W-50, API SG or higher, JASO MA compliant motorcycle specific oil Cooling Cooling System: Liquid cooling with radiator and fan Ignition Ignition System: Digital CDI with variable ignition timing 🔧 Transmission Standard Transmission Type: 6-speed sequential manual Clutch Type: Hydraulically actuated wet multi-plate clutch Features Final Drive: O-ring sealed chain, 525 pitch 📐 Dimensions Exterior Length Approx: Approx. 2100 mm Width Approx: Approx. 780 mm (at handlebars) Weights Dry Weight Approx: Approx. 195 kg Wet Weight Approx: Approx. 215 kg (with all fluids) Other Fuel Capacity: Approx. 21 liters 🛡️ Safety Features Ratings Safety Focus: High-performance motorcycle, emphasis on rider skill and adherence to safety precautions. Active Features Braking System: Dual front discs with radial-mount calipers, single rear disc. Suspension Design: Adjustable front forks (e.g., Showa or Marzocchi), adjustable rear monoshock. 💡 Technology Features Infotainment Instrumentation: Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature, basic warning lights. Driver Assistance Rider Aids: No electronic rider aids (ABS, traction control) typically found on this generation. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 6,000 - 10,000 km or annually, consult manual for precise interval. Valve Clearance Interval: Typically every 12,000 - 24,000 km, consult manual for precise interval. Fluid Specifications Coolant Type: Ethylene glycol based antifreeze mixture with demineralized water (typically 50/50). Brake Fluid Type: DOT 4 or DOT 5.1 recommended. Fork Oil Grade: Specify viscosity grade (e.g., 10W) and level as per manual. Known Issues Common Wear Items: Clutch wear, regulator/rectifier failure (early models), fuel pump issues, potential electrical connector corrosion. Performance Tuning Notes: Manual covers standard tuning and diagnosis; aftermarket ECU tuning may require specialized knowledge. Torque Specifications Importance Of Torques: Crucial for proper assembly and component longevity; manual lists specific values for critical fasteners. 📚 Vehicle History Brand Heritage Aprilia Legacy: Italian manufacturer with a strong racing pedigree, known for performance motorcycles. Model Evolution Tuono V990 Origin: Derived from the Aprilia RSV Mille sportbike, adapted for naked streetfighter ergonomics. Production Production Period: Produced from 2001 through early 2000s. 🏆 Awards & Recognition Recognitions Motorcycle Reviews: Highly acclaimed for its performance and handling by contemporary motorcycle publications.
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Aprilia Tuono V990 2002 2003 2004 2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Tuono V990
Model Variant:
V990
Generation
Generation:
First Generation
Codes
Platform Code:
RSV-based (shared with RSV Mille)
👋 Introduction
Market Position
Market Segment:
High-performance naked sportbike, competing with Ducati Monster, Triumph Speed Triple.
Competitive Analysis
Key Selling Points:
Powerful V-twin engine, agile handling, aggressive styling, Italian engineering.
Key Features
Manual Utility:
Essential resource for owners and mechanics for maintenance, repair, and troubleshooting, emphasizing clarity and detail.
📋 Manual Details
Coverage Areas
Years Covered:
2002, 2003, 2004, 2005
Page Count
Page Count:
186
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly, assembly, diagnosis, testing, lubrication, cooling, fuel injection, ignition, exhaust.
Drivetrain Systems:
Clutch, gearbox (transmission), final drive (chain and sprockets).
Chassis Systems:
Frame, suspension (front forks, rear shock absorber), steering, wheels, tires.
Braking Systems:
Brake system diagnosis, hydraulic components, brake fluid, caliper, master cylinder, brake lines.
Electrical Systems:
Wiring diagrams, battery, charging system, lighting, ignition system, ECU, sensors, starter motor.
Bodywork And Fixtures:
Fairings, seat, fuel tank, instrumentation, fasteners.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, chain adjustment, brake checks.
Repair Procedures:
Detailed step-by-step instructions for disassembly, assembly, and repair of all major components.
Troubleshooting Guides:
Diagnostic procedures for identifying and resolving common and uncommon issues.
Adjustment Procedures:
Carburetor/throttle body synchronization, valve clearance adjustment, suspension setup, electrical component adjustments.
Special Tool Usage:
Identification and usage instructions for specific Aprilia service tools.
Technical Depth
Depth Of Coverage:
Comprehensive, from basic checks and maintenance to complete engine and transmission rebuilds, including diagnostic procedures.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, viewable on any computer, zoomable.
Print Quality
Printability:
All pages are printable.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Software Requirements
Software Requirement:
Adobe Reader (or compatible PDF viewer)
Compatibility
Operating Systems:
Windows, Mac, Linux OS
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, four-stroke, liquid-cooled, DOHC, 8 valves
Engine Displacement:
998 cc (997.6 cc)
Bore X Stroke:
97 mm x 67.5 mm
Performance
Horsepower Approx:
120 - 130 HP (claimed, depending on specific model year/tune)
Torque Approx:
95 - 100 Nm (claimed, depending on specific model year/tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Weber Marelli or similar
Fuel Type:
Unleaded gasoline, minimum 95 RON
Lubrication
Oil Type:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA compliant motorcycle specific oil
Cooling
Cooling System:
Liquid cooling with radiator and fan
Ignition
Ignition System:
Digital CDI with variable ignition timing
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual
Clutch Type:
Hydraulically actuated wet multi-plate clutch
Features
Final Drive:
O-ring sealed chain, 525 pitch
📐 Dimensions
Exterior
Length Approx:
Approx. 2100 mm
Width Approx:
Approx. 780 mm (at handlebars)
Weights
Dry Weight Approx:
Approx. 195 kg
Wet Weight Approx:
Approx. 215 kg (with all fluids)
Other
Fuel Capacity:
Approx. 21 liters
🛡️ Safety Features
Ratings
Safety Focus:
High-performance motorcycle, emphasis on rider skill and adherence to safety precautions.
Active Features
Braking System:
Dual front discs with radial-mount calipers, single rear disc.
Suspension Design:
Adjustable front forks (e.g., Showa or Marzocchi), adjustable rear monoshock.
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature, basic warning lights.
Driver Assistance
Rider Aids:
No electronic rider aids (ABS, traction control) typically found on this generation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000 - 10,000 km or annually, consult manual for precise interval.
Valve Clearance Interval:
Typically every 12,000 - 24,000 km, consult manual for precise interval.
Fluid Specifications
Coolant Type:
Ethylene glycol based antifreeze mixture with demineralized water (typically 50/50).
Brake Fluid Type:
DOT 4 or DOT 5.1 recommended.
Fork Oil Grade:
Specify viscosity grade (e.g., 10W) and level as per manual.
Known Issues
Common Wear Items:
Clutch wear, regulator/rectifier failure (early models), fuel pump issues, potential electrical connector corrosion.
Performance Tuning Notes:
Manual covers standard tuning and diagnosis; aftermarket ECU tuning may require specialized knowledge.
Torque Specifications
Importance Of Torques:
Crucial for proper assembly and component longevity; manual lists specific values for critical fasteners.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Italian manufacturer with a strong racing pedigree, known for performance motorcycles.
Model Evolution
Tuono V990 Origin:
Derived from the Aprilia RSV Mille sportbike, adapted for naked streetfighter ergonomics.
Production
Production Period:
Produced from 2001 through early 2000s.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Highly acclaimed for its performance and handling by contemporary motorcycle publications.
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