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APRILIA Tuono V4 1100 Factory User Manual

APRILIA Tuono V4 1100 Factory
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SERVICE STATION MANUAL
2Q000504
Tuono V4 1100 Factory

Table of Contents

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APRILIA Tuono V4 1100 Factory Specifications

General IconGeneral
Displacement1077 cc
Bore x Stroke81 x 52.3 mm
Compression Ratio13.6:1
Transmission6-speed cassette type gearbox
ClutchMultiplate wet clutch with mechanical slipper system
Rear BrakesSingle 220 mm disc, Brembo caliper
Front Tire120/70 ZR 17
Width810 mm
Height1090 mm
Seat Height825 mm
Dry Weight185 kg
Engine TypeAprilia V4 4-stroke, liquid cooled, double overhead camshaft (DOHC), four valves per cylinder
Max Power175 hp (129 kW) @ 11, 350 rpm
Max Torque121 Nm @ 9, 000 rpm
Fuel SystemElectronic fuel injection
Exhaust4-2-1 system
FrameAluminum dual beam
Front SuspensionÖhlins NIX 43 mm fork, fully adjustable
Rear SuspensionÖhlins monoshock, fully adjustable
Front BrakesDual 330 mm discs, Brembo M50 monobloc calipers
ABSCornering ABS
WheelsAluminum alloy
Rear Tire200/55 ZR 17
Fuel Tank Capacity18.5 L

Summary

Pre-Delivery

Pre-delivery Checks

Checks to be performed before delivering the motorcycle.

Characteristics

Safety Rules

Specific safety advice for handling hazardous substances and conditions.

Special Tools

Special Tools

List of special tools with stores codes and descriptions for engine support and containment.

Maintenance

Scheduled Maintenance Table

Table detailing maintenance tasks and intervals in miles/kilometers for US-LATAM market.

Scheduled Maintenance Table for Asia/Pacific Market

Table detailing maintenance tasks and intervals in kilometers/months for Asia/Pacific market.

Electrical System

Components Arrangement

Diagram showing the location of various electrical components on the motorcycle.

Electrical System Installation

Details on materials and quantities for electrical system installation and cable routing.

Special Checks for Cable Connection and Routing

Importance of proper connection and tightening of security-locks for critical connectors.

Engine from Vehicle

Vehicle Preparation

Operations to perform before removing the engine, such as removing fuel tank and battery.

Removing the Engine from the Vehicle

Step-by-step procedure for draining coolant and oil before engine removal.

Engine

Engine Diagram

Diagram of the engine with numbered key indicating cylinder locations.

Combustion Sequence and Angles

The order and angles of cylinder firing in the engine.

Gearbox

Exploded view and torque specifications for gearbox components.

Removing the Gearbox

Steps for removing the gearbox selector, clutch housing, gear sensor, Seeger ring, and oil pump gear.

Desmodromic Gearbox Control Rod Drum Roller Cage, Alternator Side

Procedure to remove the desmodromic gearbox control rod drum roller cage.

Checking the Primary Shaft

Characteristic wear limits for selector gear splines and shaft seats.

Starter Motor Removal

Procedures for removing and installing the starter motor.

Power Supply

Fuel System Layout

Fuel system layout diagram with key for components like injectors, throttle bodies, and fuel tank.

Fuel Pump

Information on the fuel pump, its function, and layout.

Removing the Fuel Pump

Steps to remove the fuel pump, including disconnecting the tank and safety plate.

Suspensions

Front Suspension

Section dedicated to the front suspension system.

Front Fork (Ohlins ASC)

Exploded view and torque specifications for front fork components (Ohlins ASC).

Front Fork (Sachs)

Exploded view and torque specifications for Sachs front fork components.

Front Fork Adjustment

Information on standard and racing adjustments for front fork settings, including ASC mode.

Tuono V4 1100 (Sachs fork) Adjustments

Details on adjuster screws for rebound, compression, and spring preload on Sachs forks.

Standard Adjustment (Road Use)

Recommended standard settings for rebound, compression, and spring preload for road use.

Racing Adjustment (Track Use Only)

Settings for racing use, including rebound, compression, and spring preload adjustments.

Tuono V4 1100 Factory (Ohlins fork - ASC) Adjustments

Details on electronic adjustment for Ohlins forks with ASC system.

Removing the Fork Legs

Step-by-step instructions to remove front fork stanchions, including disconnecting electrical components.

Rear Shock Absorbers

Exploded view and torque specifications for rear shock absorber components.

Rear Shock Absorber Adjustment

Procedure for adjusting rear shock absorber rebound, compression, and spring preload.

Chassis

Chassis Components

Exploded view and torque specifications for chassis mounting screws and couplings.

Front Wheel

Exploded view and torque specifications for front wheel axle nut and brake disc screws.

Front Wheel Removal

Steps to remove the front wheel, including supporting the motorcycle and removing mudguard.

Front Wheel Bearings Check

Procedures for checking front wheel bearings' rotation and play.

Rear Wheel

Exploded view of the rear wheel components.

Rear Wheel Rim Check

Checks for rear wheel rim eccentricity and bearing condition.

Rear Sprocket Support Removal

Procedure for removing the rear sprocket support assembly.

Rear Wheel Bearings Check

Procedures for checking rear wheel bearings' rotation and play.

Swingarm

Exploded view and torque specifications for rear swingarm components.

Removing the Swingarm

Steps to remove the swingarm, including detaching brake caliper and front sprocket cover.

Braking System

ABS Control Unit

Torque specifications for ABS control unit mounting screws and oil tubes.

ABS Operating Diagram

Diagram illustrating the ABS functional layout and key.

ABS Operation

General specifications and stages of ABS operation, including brake activation and pressure reduction.

ABS Fault Diagnosis Guide

Foreword on ABS warning lights, system deactivation, and fault detection logic.

Cooling System

Circuit Diagram

Diagram of the self-bleeding cooling system with key components identified.

System Type: Cooling

Description of the cooling system components: pump, thermostat, radiator, fans, expansion tank.

Cooling Components

Torque specifications for radiator and expansion tank mounting screws.

Water Pump

Torque specifications for water pump mounting screws.

Electric Fan Removal

Procedures for removing and installing the electric fan.

Coolant Replacement

Steps for removing fairings, draining coolant, and removing the radiator cap.

Coolant Refill

Instructions for refilling the cooling system with coolant via radiator and expansion tank.

Bodywork

Seat Removal and Installation

Procedures for removing and installing the tail fairing and passenger saddle.

Passenger Saddle Installation and Removal

Procedures for installing and removing the passenger saddle.

Rider Saddle Removal and Installation

Steps to remove and install the rider saddle using a hex key and unscrewing fixing screws.

Driving Mirrors

Procedure for removing and checking driving mirrors, applicable to both sides.

Instrument Panel Removal

Steps to remove the instrument panel, including the brow and disconnecting connectors.

Headlight Assembly

Procedure to remove the headlight unit, including fairings and connectors.

Headlight Fairing Removal

Procedure to remove the top fairing and its components.

Front Wheelhouse Trim Removal

Procedure to remove the lower steering yoke trim element.

Taillight Assembly Removal

Procedure to remove the tail light unit, including fairing and connector.

License Plate Light Removal

Steps to remove the license plate light, including screws and connectors.

Side Body Panels Removal

Procedure to remove side fairings after removing rider saddle.

Side Fairings Removal

Steps to remove side fairings by unscrewing clips and screws.

Fairing Mounting Panels

Procedure to remove under-fairings, front fairing, front lock, and side fairings.

Left Hand Under-Fairing Removal

Procedure to remove the left hand under-fairing.

Right Hand Under-Fairing Removal

Procedure to remove the right hand under-fairing.

Central Underfairing Removal

Procedure to remove the central under-fairing after removing side fairings.

Front Mudguard Removal

Procedure to remove the front mudguard.

Rear Grab Rail Removal

Procedure to remove the passenger handle, if applicable.

Instrument Cluster Cover Removal

Procedure to remove the instrument panel cover.

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