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Aprilia Tuono 1000 2005-2009 Factory Service Manual Repair

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🏷️ Basic Information Identification Make: Aprilia Model: Tuono 1000 Model Variant: Factory Years Covered: 2005, 2006, 2007, 2008, 2009 Codes Engine Code: V990 Chassis Code: RP (This is a common Aprilia designation, specific to model generation) 👋 Introduction Market Position Motorcycle Segment: Naked Sportbike / Hyper-Naked Aprilia Positioning: The Tuono 1000 is the naked variant of the RSV Mille sportbike, offering a more upright riding position and aggressive styling for street performance. Competitive Analysis Primary Competitors: Ducati Monster S4R, Triumph Speed Triple, Yamaha FZ1, Suzuki Bandit 1200/1250, Honda CB1000R (later models). Key Features Engine Configuration: V-Twin (90-degree) Performance Focus: Torquey engine delivery suitable for spirited street riding and aggressive acceleration. Handling Characteristics: Renowned for agile handling and a well-balanced chassis, inherited from its RSV Mille sibling. 📋 Manual Details Coverage Areas Primary Coverage: Repair and Maintenance for Aprilia Tuono 1000 (2005-2009) Target Audience: Professional Technicians and DIY Mechanics with Basic Knowledge Page Count Estimated Page Count: Not explicitly stated, but typical factory service manuals are extensive (e.g., 500-1000+ pages for comprehensive coverage) Manual Type Manual Type: Factory Service Manual / Repair Manual / Workshop Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Software Requirements: Adobe PDF Reader, WinZip Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Systems: Fuel Injection, Ignition System, Cooling System, Lubrication System, Engine Mechanical (including cylinder heads, crankshaft, pistons, valves), Exhaust System Drivetrain Systems: Clutch, Transmission (gearbox, shift mechanism), Final Drive (chain and sprockets) Chassis Systems: Frame, Suspension (front forks, rear shock absorber, linkages), Steering, Wheels, Tires Braking Systems: Front and Rear Brakes (hydraulic system, calipers, discs, master cylinders), Brake Fluid Specifications Electrical Systems: Wiring Diagrams, Battery, Charging System (alternator, rectifier/regulator), Lighting System, Ignition Switch, Starter Motor, ECU (Engine Control Unit) and Sensors, Instrument Cluster Fuel System: Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Fuel Pressure Regulator Procedures Included Maintenance Procedures: Scheduled Maintenance, Oil Changes, Filter Replacements, Chain Adjustment, Brake Pad Replacement, Spark Plug Replacement, Coolant Flush Diagnostic Procedures: Troubleshooting Guides, Fault Code Interpretation (if applicable via ECU reader), Symptom-Based Diagnostics Repair Procedures: Engine Overhaul, Transmission Repair, Suspension Component Replacement, Brake System Overhaul, Electrical Component Diagnosis and Replacement, Bodywork Repairs Disassembly Assembly: Detailed step-by-step instructions for disassembling and reassembling all major components and systems. Cleaning Reinstalling: Specific guidance on cleaning parts and proper reinstallation techniques. Technical Depth Depth Of Information: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including electrical system diagnosis and repair. 📊 Manual Specifications File Format Print Quality: Full Printable - Allows users to print specific sections or the entire manual. Zoom Functionality: Zoom IN/OUT - Enabled for detailed viewing of diagrams and text. Binding Type Binding Type: Digital (PDF Download) - No physical binding. Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 90-degree V-twin, DOHC, 4 valves per cylinder Displacement: 997.6 cc (for early models, may vary slightly with specific market configurations) Bore X Stroke: 97 mm x 67.5 mm Performance Peak Horsepower: Approximately 125-130 HP (varies by specific model year and tuning) Peak Torque: Approximately 95-100 Nm (70-74 lb-ft) at around 6500 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Likely with throttle bodies from components like Keihin or Dell'Orto Fuel Type: Unleaded Gasoline (95 RON recommended) Lubrication Oil Capacity: Approx. 3.5 Liters (with filter change) Recommended Oil Grade: 10W-40 Synthetic Motorcycle Oil (e.g., Motul, Castrol, Agip/Eni) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Optional Optional Transmissions: N/A (Manual transmission only) Features Clutch Type: Hydraulically operated, wet multi-plate clutch Final Drive: O-ring sealed chain, 525 pitch Transmission Oil Grade: API GL-4, SAE 75W-90 Synthetic Gear Oil (check specific manual for exact type) 📐 Dimensions Exterior Wheelbase: Approx. 1415 mm (55.7 inches) Length: Approx. 2100 mm (82.7 inches) Width: Approx. 800 mm (31.5 inches) (excluding mirrors) Seat Height: Approx. 830 mm (32.7 inches) Weights Dry Weight: Approx. 185 kg (408 lbs) Wet Weight: Approx. 205 kg (452 lbs) (fully fueled) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety is primarily determined by rider skill and adherence to safe riding practices. No formal crash test ratings like cars apply. Active Features Braking System: High-performance radial-mount calipers (e.g., Brembo), braided steel brake lines for improved feel and consistent performance. Suspension Quality: Fully adjustable front forks (e.g., Marzocchi) and rear shock absorber, contributing to stability and control. Passive Features Frame Construction: Aluminum twin-spar frame, providing excellent rigidity and handling. Lighting: Halogen headlights for clear visibility, LED taillight. 💡 Technology Features Infotainment Instrument Cluster: Digital and Analog combination display providing speed, RPM, fuel level, engine temperature, and warning lights. ECU Features: Engine Control Unit manages fuel injection, ignition timing, and potentially other engine parameters. Diagnostics may require specific Aprilia diagnostic tools (e.g., PADS or similar). Driver Assistance ABS: ABS was not a standard or...
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Aprilia Tuono 1000 2005-2009 Factory Service Manual Repair
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Tuono 1000
Model Variant:
Factory
Years Covered:
2005, 2006, 2007, 2008, 2009
Codes
Engine Code:
V990
Chassis Code:
RP (This is a common Aprilia designation, specific to model generation)
👋 Introduction
Market Position
Motorcycle Segment:
Naked Sportbike / Hyper-Naked
Aprilia Positioning:
The Tuono 1000 is the naked variant of the RSV Mille sportbike, offering a more upright riding position and aggressive styling for street performance.
Competitive Analysis
Primary Competitors:
Ducati Monster S4R, Triumph Speed Triple, Yamaha FZ1, Suzuki Bandit 1200/1250, Honda CB1000R (later models).
Key Features
Engine Configuration:
V-Twin (90-degree)
Performance Focus:
Torquey engine delivery suitable for spirited street riding and aggressive acceleration.
Handling Characteristics:
Renowned for agile handling and a well-balanced chassis, inherited from its RSV Mille sibling.
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair and Maintenance for Aprilia Tuono 1000 (2005-2009)
Target Audience:
Professional Technicians and DIY Mechanics with Basic Knowledge
Page Count
Estimated Page Count:
Not explicitly stated, but typical factory service manuals are extensive (e.g., 500-1000+ pages for comprehensive coverage)
Manual Type
Manual Type:
Factory Service Manual / Repair Manual / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader, WinZip
Compatibility:
All Versions of Windows & Mac
📖 Manual Coverage
Systems Covered
Engine Systems:
Fuel Injection, Ignition System, Cooling System, Lubrication System, Engine Mechanical (including cylinder heads, crankshaft, pistons, valves), Exhaust System
Drivetrain Systems:
Clutch, Transmission (gearbox, shift mechanism), Final Drive (chain and sprockets)
Chassis Systems:
Frame, Suspension (front forks, rear shock absorber, linkages), Steering, Wheels, Tires
Braking Systems:
Front and Rear Brakes (hydraulic system, calipers, discs, master cylinders), Brake Fluid Specifications
Electrical Systems:
Wiring Diagrams, Battery, Charging System (alternator, rectifier/regulator), Lighting System, Ignition Switch, Starter Motor, ECU (Engine Control Unit) and Sensors, Instrument Cluster
Fuel System:
Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Fuel Pressure Regulator
Procedures Included
Maintenance Procedures:
Scheduled Maintenance, Oil Changes, Filter Replacements, Chain Adjustment, Brake Pad Replacement, Spark Plug Replacement, Coolant Flush
Diagnostic Procedures:
Troubleshooting Guides, Fault Code Interpretation (if applicable via ECU reader), Symptom-Based Diagnostics
Repair Procedures:
Engine Overhaul, Transmission Repair, Suspension Component Replacement, Brake System Overhaul, Electrical Component Diagnosis and Replacement, Bodywork Repairs
Disassembly Assembly:
Detailed step-by-step instructions for disassembling and reassembling all major components and systems.
Cleaning Reinstalling:
Specific guidance on cleaning parts and proper reinstallation techniques.
Technical Depth
Depth Of Information:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including electrical system diagnosis and repair.
📊 Manual Specifications
File Format
Print Quality:
Full Printable - Allows users to print specific sections or the entire manual.
Zoom Functionality:
Zoom IN/OUT - Enabled for detailed viewing of diagrams and text.
Binding Type
Binding Type:
Digital (PDF Download) - No physical binding.
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 90-degree V-twin, DOHC, 4 valves per cylinder
Displacement:
997.6 cc (for early models, may vary slightly with specific market configurations)
Bore X Stroke:
97 mm x 67.5 mm
Performance
Peak Horsepower:
Approximately 125-130 HP (varies by specific model year and tuning)
Peak Torque:
Approximately 95-100 Nm (70-74 lb-ft) at around 6500 RPM
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Likely with throttle bodies from components like Keihin or Dell'Orto
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Lubrication
Oil Capacity:
Approx. 3.5 Liters (with filter change)
Recommended Oil Grade:
10W-40 Synthetic Motorcycle Oil (e.g., Motul, Castrol, Agip/Eni)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Optional
Optional Transmissions:
N/A (Manual transmission only)
Features
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Final Drive:
O-ring sealed chain, 525 pitch
Transmission Oil Grade:
API GL-4, SAE 75W-90 Synthetic Gear Oil (check specific manual for exact type)
📐 Dimensions
Exterior
Wheelbase:
Approx. 1415 mm (55.7 inches)
Length:
Approx. 2100 mm (82.7 inches)
Width:
Approx. 800 mm (31.5 inches) (excluding mirrors)
Seat Height:
Approx. 830 mm (32.7 inches)
Weights
Dry Weight:
Approx. 185 kg (408 lbs)
Wet Weight:
Approx. 205 kg (452 lbs) (fully fueled)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety is primarily determined by rider skill and adherence to safe riding practices. No formal crash test ratings like cars apply.
Active Features
Braking System:
High-performance radial-mount calipers (e.g., Brembo), braided steel brake lines for improved feel and consistent performance.
Suspension Quality:
Fully adjustable front forks (e.g., Marzocchi) and rear shock absorber, contributing to stability and control.
Passive Features
Frame Construction:
Aluminum twin-spar frame, providing excellent rigidity and handling.
Lighting:
Halogen headlights for clear visibility, LED taillight.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital and Analog combination display providing speed, RPM, fuel level, engine temperature, and warning lights.
ECU Features:
Engine Control Unit manages fuel injection, ignition timing, and potentially other engine parameters. Diagnostics may require specific Aprilia diagnostic tools (e.g., PADS or similar).
Driver Assistance
ABS:
ABS was not a standard or common feature on this specific model/generation of Tuono 1000. Some later variants or aftermarket options might exist, but not typically factory.
Connectivity
Connectivity Features:
N/A (Motorcycle electronics are primarily focused on engine management and basic functions).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km (3,000-4,500 miles) or annually, whichever comes first.
Chain Lubrication Inspection:
Every 500-1000 km (300-600 miles) and adjust as needed.
Spark Plug Replacement:
Typically around 10,000-15,000 km (6,000-9,000 miles).
Valve Clearance Check:
Around 15,000-20,000 km (9,000-12,000 miles) - Critical for optimal performance and engine longevity.
Fluid Specifications
Coolant Type:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific Aprilia coolant.
Brake Fluid Type:
DOT 4 or DOT 5.1 (check manual for precise recommendation)
Fork Oil Viscosity:
Typically SAE 5W or 7.5W, capacity specified per fork leg.
Known Issues
Electrical Gremlins:
Older Aprilia models can be prone to minor electrical issues. Ensuring all connections are clean and secure is crucial. Fuel pump relays or sensor issues can sometimes occur.
Regulator Rectifier Heat:
Common on many V-twin bikes of this era; ensuring good airflow to the regulator/rectifier can help prevent premature failure.
Vibration Damping:
While spirited, the V-twin can produce noticeable vibration at certain RPMs. Some owners opt for aftermarket bar-end weights.
Chain And Sprockets Wear:
Regular cleaning and lubrication are essential for longevity, especially given the torque of the engine.
📚 Vehicle History
Brand Heritage
Aprilia Motorsport Legacy:
Aprilia has a rich history in motorcycle racing, particularly in the 125cc and 250cc Grand Prix classes, and a strong presence in Superbike racing. This racing DNA influences their production street bikes.
Model Evolution
Tuono Origin:
The Tuono 1000 is derived from the Aprilia RSV Mille sportbike, adapting its powerful V-twin engine and sophisticated chassis for a more versatile, upright riding experience.
Generation Differences:
The 2005-2009 models represent a significant evolution from earlier Tuono generations, often featuring updated electronics, suspension components, and styling tweaks. The 'Factory' designation typically indicates higher-spec components.
Production
Manufacturing Location:
Noale, Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Journal Reviews:
The Tuono 1000 range generally received positive reviews for its potent engine, sharp handling, and aggressive character, often praised as a thrilling streetfighter.
Performance Awards:
While specific 'awards' are rare for individual model years, the platform was recognized for its performance and rideability within the naked sportbike category.
Certifications
Manual Certification:
This is a third-party produced or compiled service manual, not an official factory certification document, but aims to replicate factory technical data.
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