2005–2009 Aprilia Tuono 1000 OEM Workshop & Repair Manual (P/N 1306 5 / 8104982 UK)

This Aprilia OEM workshop manual covers maintenance and repair of the 2005–2009 Tuono 1000 with the V990 NG engine. The English chassis workshop publication is P/N 8104982 UK, with cover code 1306 5.

Text search, navigation, and wiring detail: The main text supports search, and 126 embedded bookmarks provide chapter and subsection navigation. Labels within diagram images are not searchable. Some small pin numbers and wire codes in the full wiring diagram remain difficult to read even when enlarged.

• Fuel injection: Throttle body disassembly and inspection, fuel pump and filter removal, cylinder synchronization, and CO adjustment using Axone 2000.

• ECU and electrical diagnosis: Fault interpretation, TPS self-learning, ECU initialization, CAN line operation, immobilizer functions, and electrical component tests.

• Suspension repair: Front fork oil and seal replacement, steering bearing play adjustment, rear shock removal, and suspension linkage inspection.

• Wheels and final drive: Wheel and sprocket-carrier bearing replacement, swingarm service, drive-chain adjustment, and chain-slider inspection.

• Brakes and clutch: Front and rear pad replacement, brake-disc wear and runout checks, and hydraulic brake and clutch bleeding.

• Engine and cooling: V990 NG engine removal and installation, mounting torque tables, cooling-system diagrams, and coolant filling and air-release procedures.

Aprilia wrote this manual for its dealers and qualified mechanics, assuming familiarity with mechanical fundamentals and basic repair procedures.

Fuel Injection and Axone Setup

The throttle body section covers injector and fuel-pressure regulator removal, control-lever replacement, and throttle-shaft axial-play inspection. Fuel pump procedures extend to the fuel level sensor and delivery filter.

Axone tables explain live data, device activation, fault status, and freeze-frame records. TPS self-learning, stepper-motor reset, and ECU initialization are distinguished, including the activation required when a replacement ECU is installed.

Cylinder synchronization and CO procedures distinguish Variant 1 with standard exhausts from Variant 2 with open exhausts and racing mapping. A separate note addresses the lower CO readings associated with a complete Akrapovic exhaust system. Racing settings are restricted to track use.

Electrical Faults and ECU Mapping

ECU connector A and B pinout tables identify connections and signal types. The Electric Parts Inspection Table supplies test specifications for sensors, ignition coils, the generator, and charging voltage. The wiring diagram and Injection System Diagram show the associated circuits and components.

The CAN line section describes the combined warning-light and display symptoms of lost communication. Together with Axone status information, this helps distinguish an ECU-to-instrument-panel communication problem from an individual sensor fault.

Section 7.1.8 records the ECU and wiring changes associated with frame number ZD4RR00004S003947, including the change from a three-pin to a two-pin pickup-sensor connector. Its replacement-ECU table distinguishes compatibility with mappings 664584 and 664583.

Immobilizer coverage includes key recognition and key-code storage. Programming additional keys requires the dealer’s Master Key.

Forks, Bearings, and Final Drive

Fork inspection covers straightness, spring length, bushing condition, and oil-level specifications. Standard suspension settings are distinguished from optional Öhlins fork and rear shock settings, with separate Showa and Öhlins fork-clamp torque entries.

Wheel and final-drive sections cover bearing replacement, sprocket-carrier vibration dampers, and rear sprocket service. Illustrated special-tool references include bearing extractor 8140180 and swingarm-pivot/engine-bracket tool 8140191.

Wheel-bearing assembly cautions address the risk of forcing the retaining circlip during installation. The final-drive section explains how the sprocket-carrier assembly can fall out during wheel handling and damage the rear sprocket.

Engine, Cooling, and Brake Service

The engine chapter covers removal, installation, related connections, and mounting hardware. Internal engine and gearbox overhaul procedures are not included. The reference section lists the separate Engine Technical Manual, P/N 8140747 UK, which is not part of this file.

Cooling coverage includes a system diagram and coolant filling and air-release procedures. Brake-system diagrams accompany disc inspection limits and separate bleeding procedures for the master cylinders and calipers.

The Scheduled Maintenance Chart and lubricant table support service planning. Reference data includes component-specific tightening torques, fluid capacities, wear limits, adjustment specifications, and NGK R DCPR9E spark plug data.

Follow the factory safety precautions for supporting the motorcycle during engine removal and for handling fuel and hydraulic brake fluid.

English Workshop Manual PDF

Supplied as one printable English PDF. The 279-page file comprises 277 manual pages plus the front and back covers, with both cover pages already included in the total.