Aprilia Tuono 1000 2005-2011 Workshop Service Repair Manual
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🏷️ Basic Information
Identification
Make:
Aprilia
Model:
Tuono 1000
Model Years Covered:
2005, 2006, 2007, 2008, 2009, 2010, 2011
Codes
Vehicle Platform Code:
RP (derived from RSV Mille platform)
👋 Introduction
Market Position
Positioning:
High-performance naked sportbike, derived from the RSV Mille superbike.
Competitive Analysis
Competitors:
Ducati Monster, Triumph Speed Triple, Aprilia RSV4 (later models).
Key Features
Engine Type:
V-Twin (Rotax 60-degree V-twin)
Frame Construction:
Aluminum Twin-Spar Frame
Suspension Type:
Upside-down front forks, Monoshock rear suspension
Braking System:
High-performance disc brakes, radial calipers
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Workshop Service Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Repair, Overhaul
Page Count
Estimated Pages:
Hundreds (exact count not specified, but described as extensive)
Manual Type
Type:
Official Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Top End (Cylinder Head, Valves, Camshafts), Lubrication System, Clutch, Crankshaft, Transmission
Fuel System:
Fuel Delivery, Injection System (EFI), Carburetor (if applicable to specific sub-models/markets)
Cooling System:
Radiator, Coolant Flow, Water Pump, Thermostat
Chassis:
Wheels/Tires, Final Drive (Chain/Sprocket), Brakes (Front/Rear), Suspension (Front/Rear), Steering, Frame
Electrical System:
Wiring Diagrams, Ignition System, Lighting, Instrumentation, Starter, Charging System, ECU Diagnosis
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Inspections
Repair:
Step-by-step repair procedures for all major components
Disassembly Reassembly:
Complete disassembly and reassembly instructions
Troubleshooting:
Diagnostic procedures for common and uncommon faults
Technical Data:
Specifications, torque values, clearances, tolerances
Technical Depth
Depth:
Comprehensive (suitable for DIY and experienced mechanics)
Illustrations:
Hundreds of photos and illustrations
Detail Level:
Detailed substeps, notes, cautions, and warnings
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All PC-based Windows operating systems and Mac
Print Quality
Printability:
Printable without restriction (entire manual or select pages)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Requirements
Software:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, 60° V-twin cylinder, liquid-cooled, DOHC, 4 valves per cylinder
Displacement:
997.6 cc (typical for this generation)
Bore X Stroke:
97 mm x 67.5 mm (typical)
Compression Ratio:
10.8:1 to 11.5:1 (depending on specific year/tune)
Performance
Horsepower Output:
Approx. 125-130 hp @ 9500 rpm (typical)
Torque Output:
Approx. 99 Nm (73 lb-ft) @ 7000 rpm (typical)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with twin injectors per cylinder
Fuel Type:
Unleaded gasoline, minimum 95 RON
🔧 Transmission
Standard
Transmission Type:
6-speed sequential, constant mesh
Features
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Final Drive:
O-ring sealed chain, 525 pitch (typical)
📐 Dimensions
Exterior
Wheelbase:
Approx. 1410-1420 mm (55.5-55.9 inches)
Seat Height:
Approx. 830-840 mm (32.7-33.1 inches)
Weights
Dry Weight:
Approx. 185-190 kg (408-419 lbs)
Fuel Tank Capacity:
Approx. 18 liters (4.75 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is typically assessed through independent testing and design features rather than formal crash ratings like cars).
Active Features
Braking System Type:
Dual 320mm front discs with radial-mount 4-piston calipers; Single 220mm rear disc with 2-piston caliper
Optional ABS:
ABS was an optional feature on some models/markets during these years.
Passive Features
Lighting:
Halogen headlamps, LED taillight
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus is on performance, not advanced infotainment).
Driver Assistance
Driver Assistance Features:
Optional ABS system.
🔧 Maintenance
Service Intervals
Oil Change:
Every 6,000 km (3,700 miles) or annually, whichever comes first.
Major Service:
Typically around 12,000 km (7,500 miles) for valve clearance checks, spark plug replacement, etc.
Fluid Specifications
Engine Oil:
SAE 10W-40, API SG or higher, JASO MA certified (e.g., Motul 5100 10W-40)
Coolant:
Ethylene glycol-based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic brake fluid
Clutch Fluid:
DOT 4 hydraulic fluid (same as brake fluid)
Known Issues
Electrical Gremlins:
Some owners report minor electrical connector issues or sensor faults over time, particularly related to the wiring harness integrity.
Regulator Rectifier:
As with many bikes of this era, the regulator/rectifier can be a potential failure point, though less common than some other brands.
Fuel Pump:
Occasional reports of fuel pump issues requiring replacement.
📚 Vehicle History
Brand Heritage
Manufacturer Heritage:
Aprilia is an Italian manufacturer with a strong racing pedigree, particularly in Grand Prix motorcycle racing.
Model Evolution
Predecessor:
Derived from the RSV Mille sportbike platform.
Evolution Notes:
The Tuono 1000 was essentially a more upright, naked version of the RSV Mille, focusing on street usability and rider comfort while retaining potent performance.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Recognitions:
Widely praised by motorcycle journalists for its performance, handling, and aggressive styling. Often lauded as a rider's machine.
Ratings
Review Ratings:
Consistently received high marks for performance and handling in contemporary reviews.
Certifications
Certifications:
CE compliance (typical for European market motorcycles).
Comprehensive (suitable for DIY and experienced mechanics)
Illustrations:
Hundreds of photos and illustrations
Detail Level:
Detailed substeps, notes, cautions, and warnings
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All PC-based Windows operating systems and Mac
Print Quality
Printability:
Printable without restriction (entire manual or select pages)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Requirements
Software:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, 60° V-twin cylinder, liquid-cooled, DOHC, 4 valves per cylinder
Displacement:
997.6 cc (typical for this generation)
Bore X Stroke:
97 mm x 67.5 mm (typical)
Compression Ratio:
10.8:1 to 11.5:1 (depending on specific year/tune)
Performance
Horsepower Output:
Approx. 125-130 hp @ 9500 rpm (typical)
Torque Output:
Approx. 99 Nm (73 lb-ft) @ 7000 rpm (typical)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with twin injectors per cylinder
Fuel Type:
Unleaded gasoline, minimum 95 RON
🔧 Transmission
Standard
Transmission Type:
6-speed sequential, constant mesh
Features
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Final Drive:
O-ring sealed chain, 525 pitch (typical)
📐 Dimensions
Exterior
Wheelbase:
Approx. 1410-1420 mm (55.5-55.9 inches)
Seat Height:
Approx. 830-840 mm (32.7-33.1 inches)
Weights
Dry Weight:
Approx. 185-190 kg (408-419 lbs)
Fuel Tank Capacity:
Approx. 18 liters (4.75 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is typically assessed through independent testing and design features rather than formal crash ratings like cars).
Active Features
Braking System Type:
Dual 320mm front discs with radial-mount 4-piston calipers; Single 220mm rear disc with 2-piston caliper
Optional ABS:
ABS was an optional feature on some models/markets during these years.
Passive Features
Lighting:
Halogen headlamps, LED taillight
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus is on performance, not advanced infotainment).
Driver Assistance
Driver Assistance Features:
Optional ABS system.
🔧 Maintenance
Service Intervals
Oil Change:
Every 6,000 km (3,700 miles) or annually, whichever comes first.
Major Service:
Typically around 12,000 km (7,500 miles) for valve clearance checks, spark plug replacement, etc.
Fluid Specifications
Engine Oil:
SAE 10W-40, API SG or higher, JASO MA certified (e.g., Motul 5100 10W-40)
Coolant:
Ethylene glycol-based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic brake fluid
Clutch Fluid:
DOT 4 hydraulic fluid (same as brake fluid)
Known Issues
Electrical Gremlins:
Some owners report minor electrical connector issues or sensor faults over time, particularly related to the wiring harness integrity.
Regulator Rectifier:
As with many bikes of this era, the regulator/rectifier can be a potential failure point, though less common than some other brands.
Fuel Pump:
Occasional reports of fuel pump issues requiring replacement.
📚 Vehicle History
Brand Heritage
Manufacturer Heritage:
Aprilia is an Italian manufacturer with a strong racing pedigree, particularly in Grand Prix motorcycle racing.
Model Evolution
Predecessor:
Derived from the RSV Mille sportbike platform.
Evolution Notes:
The Tuono 1000 was essentially a more upright, naked version of the RSV Mille, focusing on street usability and rider comfort while retaining potent performance.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Recognitions:
Widely praised by motorcycle journalists for its performance, handling, and aggressive styling. Often lauded as a rider's machine.
Ratings
Review Ratings:
Consistently received high marks for performance and handling in contemporary reviews.
Certifications
Certifications:
CE compliance (typical for European market motorcycles).