Aprilia ETV 1000 Caponord Complete Workshop Service Repair Manual 2001 2002 2003 2004 2005 2006 2007
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🏷️ Basic Information Identification Make: Aprilia Model: ETV 1000 Caponord Model Variant: Standard/ABS (where applicable for the years covered) Motorcycle Type: Adventure Touring / Sport Touring Generation Generation: First Generation Generation Years: 2001-2007 Codes Engine Code: Rotax 990 V60 Magnesium (V-twin) Chassis Code: ETV 1000 👋 Introduction Market Position Segment: Adventure Touring / All-Road Motorcycle Target Audience: Riders seeking a capable long-distance touring motorcycle with off-road or unpaved road capability. Competitive Analysis Key Competitors: BMW R1150GS/R1200GS, Honda VFR/Varadero, Triumph Tiger, Suzuki V-Strom, Ducati Multistrada (early models). Key Features Engine Layout: Powerful 990cc V-twin engine offering strong torque and acceleration. Suspension: Long travel suspension for comfort and off-road compliance. Ergonomics: Upright riding position suitable for long-distance comfort. Versatility: Designed for both highway touring and tackling varied road conditions. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Procedures Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Electrical Systems, Component Overhaul Page Count Estimated Page Count: Approximately 500+ pages (typical for a comprehensive workshop manual of this era) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF compatible) 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, lubrication, cooling, fuel delivery, ignition, exhaust, performance tuning Transmission: Gearbox disassembly, assembly, clutch operation, final drive (chain and sprockets) Chassis And Suspension: Frame, front forks (WP Suspension), rear shock absorber ( Sachs or similar), wheel bearings, steering head Brakes: Brake system maintenance (front and rear), caliper overhaul, master cylinder, fluid replacement, ABS system (if equipped) Electrical: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, lighting, instrumentation, ignition system, ECU diagnostics Fuel System: Fuel injection system (throttle bodies, injectors, fuel pump, pressure regulator), fuel tank, fuel lines Bodywork And Trim: Fairing removal and installation, seat, luggage systems (optional panniers/top box mounting), aesthetic components Procedures Included Maintenance: Oil changes, filter replacements, chain adjustment, tire pressure checks, spark plug replacement, coolant flush, brake fluid replacement Troubleshooting: Diagnostic flowcharts for common problems, electrical fault finding, engine performance issues Repair: Detailed step-by-step repair instructions for all major and minor components Overhaul: Engine internal component overhaul, gearbox rebuild, suspension damper servicing Specifications: Torque values, clearances, fluid capacities, electrical resistance values Technical Depth Depth: Comprehensive: Covers everything from basic rider maintenance to full engine and electrical system overhauls. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (typical for well-produced PDFs) Print Quality Quality: High quality, enabling clear printing of text and diagrams Image Clarity: Clear, high-resolution images and diagrams for visual guidance Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, V-twin (60-degree V-angle), liquid-cooled, DOHC, 4 valves per cylinder Displacement: 998 cc (998 cubic centimeters) Bore X Stroke: 97 mm x 68 mm Performance Horsepower: Approximately 110-115 HP (peak, depending on specific model year and region) Torque: Approximately 96-100 Nm (peak, depending on specific model year and region) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual throttle bodies Fuel Type: Unleaded gasoline (minimum 95 RON recommended) Fuel Tank Capacity: 25 Liters (approx. 6.6 US gallons) Ignition Ignition System: Digital electronic ignition with separate ignition coils for each cylinder Lubrication Lubrication System: Wet sump, forced lubrication Cooling Cooling System: Liquid-cooled 🔧 Transmission Standard Gearbox: 6-speed sequential manual transmission Optional Optional Transmission: N/A (Standard manual gearbox) Features Clutch Type: Hydraulically operated, wet multi-plate clutch Final Drive: O-ring sealed chain, 525 pitch Fluid Specifications Transmission Oil: API GL-4 or GL-5, SAE 80W-90 gear oil (refer to manual for exact Aprilia specification) 📐 Dimensions Exterior Length: Approx. 2230 mm (87.8 in) Width: Approx. 860 mm (33.9 in) (at handlebars) Height: Approx. 1360 mm (53.5 in) (at windshield) Weights Dry Weight: Approx. 210-215 kg (463-474 lbs) Wet Weight: Approx. 240-245 kg (529-540 lbs) (fully fueled) Gross Vehicle Weight Rating: Refer to chassis plate/manual (typically around 450-480 kg) 🛡️ Safety Features Ratings ABS: Optional Anti-lock Braking System (ABS) available on some models within the specified years. Active Features Braking System Front: Dual 320 mm discs, radial-mount calipers (e.g., Brembo) Braking System Rear: Single 240 mm disc, twin-piston caliper Passive Features Lighting: Dual Halogen headlights, LED taillight and indicators Frame Construction: Aluminum alloy twin-spar frame 💡 Technology Features Infotainment Instrumentation: Analog tachometer and speedometer, digital display for odometer, trip meter, fuel level, coolant temperature, and clock. Warning lights for various systems. Driver Assistance ABS: Optional ABS system on select models, which can be diagnosed and serviced using procedures within the manual. Connectivity Wiring Harness: Comprehensive wiring diagrams provided for diagnosis and repair of the electrical system. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 - 10,000 km (3,700 - 6,200 miles) or annually, whichever comes first (refer to manual for exact specification). Valve Clearance Check: Every 12,000 - 20,000 km (7,500 - 12,400 miles) (refer to manual for exact specification). Spark Plug...
Comprehensive: Covers everything from basic rider maintenance to full engine and electrical system overhauls.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (typical for well-produced PDFs)
Print Quality
Quality:
High quality, enabling clear printing of text and diagrams
Image Clarity:
Clear, high-resolution images and diagrams for visual guidance
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, V-twin (60-degree V-angle), liquid-cooled, DOHC, 4 valves per cylinder
Displacement:
998 cc (998 cubic centimeters)
Bore X Stroke:
97 mm x 68 mm
Performance
Horsepower:
Approximately 110-115 HP (peak, depending on specific model year and region)
Torque:
Approximately 96-100 Nm (peak, depending on specific model year and region)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies
Fuel Type:
Unleaded gasoline (minimum 95 RON recommended)
Fuel Tank Capacity:
25 Liters (approx. 6.6 US gallons)
Ignition
Ignition System:
Digital electronic ignition with separate ignition coils for each cylinder
Lubrication
Lubrication System:
Wet sump, forced lubrication
Cooling
Cooling System:
Liquid-cooled
🔧 Transmission
Standard
Gearbox:
6-speed sequential manual transmission
Optional
Optional Transmission:
N/A (Standard manual gearbox)
Features
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Final Drive:
O-ring sealed chain, 525 pitch
Fluid Specifications
Transmission Oil:
API GL-4 or GL-5, SAE 80W-90 gear oil (refer to manual for exact Aprilia specification)
📐 Dimensions
Exterior
Length:
Approx. 2230 mm (87.8 in)
Width:
Approx. 860 mm (33.9 in) (at handlebars)
Height:
Approx. 1360 mm (53.5 in) (at windshield)
Weights
Dry Weight:
Approx. 210-215 kg (463-474 lbs)
Wet Weight:
Approx. 240-245 kg (529-540 lbs) (fully fueled)
Gross Vehicle Weight Rating:
Refer to chassis plate/manual (typically around 450-480 kg)
🛡️ Safety Features
Ratings
ABS:
Optional Anti-lock Braking System (ABS) available on some models within the specified years.
Active Features
Braking System Front:
Dual 320 mm discs, radial-mount calipers (e.g., Brembo)
Braking System Rear:
Single 240 mm disc, twin-piston caliper
Passive Features
Lighting:
Dual Halogen headlights, LED taillight and indicators
Frame Construction:
Aluminum alloy twin-spar frame
💡 Technology Features
Infotainment
Instrumentation:
Analog tachometer and speedometer, digital display for odometer, trip meter, fuel level, coolant temperature, and clock. Warning lights for various systems.
Driver Assistance
ABS:
Optional ABS system on select models, which can be diagnosed and serviced using procedures within the manual.
Connectivity
Wiring Harness:
Comprehensive wiring diagrams provided for diagnosis and repair of the electrical system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 - 10,000 km (3,700 - 6,200 miles) or annually, whichever comes first (refer to manual for exact specification).
Valve Clearance Check:
Every 12,000 - 20,000 km (7,500 - 12,400 miles) (refer to manual for exact specification).
Spark Plug Replacement:
Every 12,000 - 24,000 km (7,500 - 15,000 miles) (depending on plug type, refer to manual).
Fluid Specifications
Engine Oil Type:
Synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA certified). Consult manual for Aprilia specific recommendation.
Engine Oil Capacity:
Approx. 3.3 - 3.5 Liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water. Consult manual for Aprilia specific type.
Brake Fluid Type:
DOT 4 or DOT 5.1 (consult manual for precise specification and any ABS system requirements).
Known Issues
Common Concerns:
Potential issues can include stator failure, regulator/rectifier issues, voltage regulator problems, early ABS sensor failures, and occasional fuel pump issues. The manual will detail diagnosis and repair for these.
Maintenance Tip:
Regular inspection of electrical connectors and grounds is crucial for electrical system reliability.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its performance-oriented motorcycles, particularly in racing.
Model Evolution
Introduction Year:
The ETV 1000 Caponord was introduced in 2001.
Development Purpose:
Developed to compete in the growing adventure-touring segment, offering a blend of on-road comfort and off-road capability.
Production
Production Period:
2001-2007 (as covered by this manual)
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Award Status:
No specific widely publicized awards are readily associated with this particular model year range. Its market success was based on its capability and value proposition in the adventure-touring segment.
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