Aprilia Tuono 1000 2005-2009 Repair Service Manual
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🏷️ Basic Information Identification Make: Aprilia Model: Tuono 1000 Model Variant: Tuono 1000 R (likely, given the era and performance focus) Generation Generation Designation: Second Generation (RP generation) Generation Years: 2006-2010 (though this manual covers up to 2009 of the 2005 platform, indicating overlap or continued use of the engine/chassis) Codes Chassis Code: RP 👋 Introduction Market Position Motorcycle Segment: Naked Sportbike / Hyper-Naked Performance Focus: High-performance, track-day oriented motorcycle derived from the RSV Mille sportbike. Competitive Analysis Key Competitors: Ducati Monster series, Triumph Speed Triple, Yamaha FZ1, Suzuki Bandit 1200/1250, Kawasaki Z1000. Key Features Of Vehicle Engine Type: V-Twin (998cc) Handling Characteristics: Renowned for sharp handling, stiff chassis, and advanced suspension for its class. Key Features Of Manual Manual Benefit: Empowers owners and technicians with factory-level knowledge for effective maintenance and repair. Manual Advantage: Provides step-by-step instructions, critical specifications, and troubleshooting guidance, bridging the gap between owner knowledge and professional service. 📋 Manual Details Coverage Areas Covered Years: 2005, 2006, 2007, 2008, 2009 Specific Models Covered: Aprilia Tuono 1000 Page Count Estimated Page Count: Estimates vary widely for PDF service manuals, but typically range from 300-800 pages for comprehensive coverage of a motorcycle of this era. Manual Type Manual Type: Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, maintenance, tuning, lubrication, cooling system, fuel system, ignition system, exhaust system, engine management (ECU diagnostics where applicable). Transmission: Clutch operation, gearbox disassembly and assembly, shifting mechanism, lubrication, troubleshooting. Chassis And Suspension: Frame inspection, fork overhaul and adjustment, rear shock absorber maintenance and adjustment, swingarm service, steering head bearing service. Brakes: Front and rear brake system maintenance, hydraulic system bleeding, caliper overhaul, disc inspection, brake pad replacement, master cylinder service. Electrical System: Wiring diagrams, battery maintenance, charging system (alternator/stator, rectifier/regulator), lighting system, ignition system components, starting system, instrument panel functions, sensor testing. Fuel System: Fuel injection system (throttle bodies, injectors, fuel pump, pressure regulator), fuel tank maintenance, fuel lines. Bodywork And Fairings: Fairing removal and installation, seat maintenance, component access. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel), chain adjustment and lubrication, tire pressure checks, brake fluid checks, coolant checks. Disassembly And Assembly: Component-level disassembly and reassembly for repair and overhaul. Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides. Technical Specifications: Torque values, clearances, fluid capacities, electrical specifications, engine timings. Cleaning And Reinstalling: Proper procedures for cleaning and reinstalling components after service. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and chassis component overhauls. Suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format File Type: PDF Print Quality Printable: Yes (Full Printable) Zoom Capability: Yes (Zoom IN/OUT) Binding Type Binding: Digital Download (PDF) Paper Type Paper Quality Digital: N/A (Digital) Requirements Software Requirements: Adobe PDF Reader, WinZip Operating System Compatibility: All Versions of Windows & Mac Delivery Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Code: Rotax 998 V990 (shared with RSV Mille) Engine Type: Four-stroke, liquid-cooled, 60-degree V-twin Displacement: 997.6 cc (60.87 cu in) Bore X Stroke: 97 mm x 67.5 mm (3.82 x 2.66 in) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower Peak: Approximately 125-130 hp @ 9,500 rpm (varies slightly by year/tune) Torque Peak: Approximately 98-100 Nm (72-74 lb-ft) @ 7,000 rpm (varies slightly by year/tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - typically Magneti Marelli or similar, with dual injectors per cylinder. Throttle Body Size: 54 mm (common for this generation) Fuel Type: Unleaded gasoline, minimum 95 octane (RON) Lubrication Oil Type: Synthetic motorcycle oil, SAE 10W-40 or 15W-50 depending on climate (refer to manual for specific API/JASO ratings). Oil Capacity: Approximately 3.4-3.8 liters (3.6-4.0 US qt) with filter change. Cooling System Coolant Type: Ethylene glycol based coolant, 50/50 mix with distilled water. 🔧 Transmission Standard Transmission Type: 6-speed sequential manual gearbox Clutch Type: Hydraulically actuated, wet multi-plate clutch. Features Gear Ratios: Specific ratios would be detailed in the manual, but generally geared for strong acceleration and top-end performance. Final Drive: O-ring sealed chain drive 📐 Dimensions Exterior Wheelbase: Approximately 1410-1425 mm (55.5-56.1 in) - exact specification varies by year. Seat Height: Approximately 830-840 mm (32.7-33.1 in) Weights Dry Weight: Approximately 195-205 kg (430-452 lbs) - depending on options and specific year. Wet Weight: Approximately 220-230 kg (485-507 lbs) - with all fluids. 🛡️ Safety Features Ratings Safety Ratings: Motorcycles of this era typically do not have standardized crash ratings like automobiles. Safety is inherent in design and rider skill. Active Features Braking System: High-performance Brembo radial-mount calipers with dual front discs and a single rear disc. Some models may have optional ABS, though less common on this generation Tuono. Suspension Adjustability: Fully adjustable front forks...
Renowned for sharp handling, stiff chassis, and advanced suspension for its class.
Key Features Of Manual
Manual Benefit:
Empowers owners and technicians with factory-level knowledge for effective maintenance and repair.
Manual Advantage:
Provides step-by-step instructions, critical specifications, and troubleshooting guidance, bridging the gap between owner knowledge and professional service.
📋 Manual Details
Coverage Areas
Covered Years:
2005, 2006, 2007, 2008, 2009
Specific Models Covered:
Aprilia Tuono 1000
Page Count
Estimated Page Count:
Estimates vary widely for PDF service manuals, but typically range from 300-800 pages for comprehensive coverage of a motorcycle of this era.
Proper procedures for cleaning and reinstalling components after service.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and chassis component overhauls. Suitable for professional technicians and advanced DIY mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printable:
Yes (Full Printable)
Zoom Capability:
Yes (Zoom IN/OUT)
Binding Type
Binding:
Digital Download (PDF)
Paper Type
Paper Quality Digital:
N/A (Digital)
Requirements
Software Requirements:
Adobe PDF Reader, WinZip
Operating System Compatibility:
All Versions of Windows & Mac
Delivery
Delivery Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Code:
Rotax 998 V990 (shared with RSV Mille)
Engine Type:
Four-stroke, liquid-cooled, 60-degree V-twin
Displacement:
997.6 cc (60.87 cu in)
Bore X Stroke:
97 mm x 67.5 mm (3.82 x 2.66 in)
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower Peak:
Approximately 125-130 hp @ 9,500 rpm (varies slightly by year/tune)
Torque Peak:
Approximately 98-100 Nm (72-74 lb-ft) @ 7,000 rpm (varies slightly by year/tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - typically Magneti Marelli or similar, with dual injectors per cylinder.
Throttle Body Size:
54 mm (common for this generation)
Fuel Type:
Unleaded gasoline, minimum 95 octane (RON)
Lubrication
Oil Type:
Synthetic motorcycle oil, SAE 10W-40 or 15W-50 depending on climate (refer to manual for specific API/JASO ratings).
Oil Capacity:
Approximately 3.4-3.8 liters (3.6-4.0 US qt) with filter change.
Cooling System
Coolant Type:
Ethylene glycol based coolant, 50/50 mix with distilled water.
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual gearbox
Clutch Type:
Hydraulically actuated, wet multi-plate clutch.
Features
Gear Ratios:
Specific ratios would be detailed in the manual, but generally geared for strong acceleration and top-end performance.
Final Drive:
O-ring sealed chain drive
📐 Dimensions
Exterior
Wheelbase:
Approximately 1410-1425 mm (55.5-56.1 in) - exact specification varies by year.
Seat Height:
Approximately 830-840 mm (32.7-33.1 in)
Weights
Dry Weight:
Approximately 195-205 kg (430-452 lbs) - depending on options and specific year.
Wet Weight:
Approximately 220-230 kg (485-507 lbs) - with all fluids.
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles of this era typically do not have standardized crash ratings like automobiles. Safety is inherent in design and rider skill.
Active Features
Braking System:
High-performance Brembo radial-mount calipers with dual front discs and a single rear disc. Some models may have optional ABS, though less common on this generation Tuono.
Suspension Adjustability:
Fully adjustable front forks (preload, compression, rebound) and rear shock absorber (preload, compression, rebound) for customizable handling and stability.
Passive Features
Chassis Construction:
Lightweight and rigid aluminum alloy twin-spar frame for optimal rigidity and feedback.
💡 Technology Features
Infotainment
Infotainment System:
No traditional infotainment system; focus is on rider feedback and mechanical precision. Features a digital LCD display with essential information (speed, RPM, fuel, temperature, odometer).
Driver Assistance
Rider Aids:
Primarily rider-controlled. ABS was an option on some models, but not standard across the range for these years.
Engine Management
ECU Type:
Electronic Control Unit (ECU) managing fuel injection and ignition timing. Manual provides diagnostic codes and parameters.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000-7,500 km (3,700-4,700 miles) or annually, whichever comes first. Refer to the specific manual for exact intervals.
Spark Plug Replacement Interval:
Typically around 12,000-16,000 km (7,500-10,000 miles) or as specified by the manufacturer.
Coolant Flush Interval:
Every 2-3 years or 24,000 km (15,000 miles).
Fluid Specifications
Brake Fluid Type:
DOT 4 or DOT 5.1 (check manual for specific recommendation).
Clutch Fluid Type:
DOT 4 or DOT 5.1 (same as brake fluid, hydraulic system).
Fork Oil Type:
Specific viscosity (e.g., Showa SS-02, SAE 10W or equivalent) and quantity required for each fork leg.
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals, steering head bearings, fuel pump (can be sensitive to fuel quality).
Potential Electrical Issues:
Regulator/rectifier failure (though improved on later models), wiring harness connections can sometimes be a point of concern if not maintained.
Engine Performance Quirks:
Early models had some snatchiness in throttle response; mapping updates or aftermarket tuners often address this. Valve clearance checks are critical for optimal performance and longevity.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Aprilia has a strong heritage in motorcycle racing, particularly in Grand Prix and Superbike championships, which heavily influences their road-going performance models.
Model Evolution
Tuono Evolution:
The Tuono 1000 is the naked sportbike variant of the RSV Mille sportbike, sharing its engine and chassis but with revised ergonomics, suspension tuning, and styling for a more aggressive street presence and versatile performance.
Production
Manufacturing Location:
Italy
Production Period:
The Tuono 1000 R was produced from roughly 2002 through 2010, with the 2005-2009 models belonging to the second generation.
🏆 Awards & Recognition
Recognitions
Motorcycle Journal Awards:
While specific awards for the 2005-2009 Tuono 1000 models are not explicitly listed here, the Tuono range generally received accolades from motorcycle publications for its exhilarating performance, sharp handling, and aggressive styling. It was often lauded as a true 'superbike for the street'.