Aprilia Sportcity 250 i.e Aprilia Tuono 1000 2005-2009 Aprilia Tuono R Factory. This is the same type of service manual your local dealer will use when doing a repair.
Below you will find free PDF files for your 2007 Aprilia owners manuals
SERVICING INFORMATIONCONTENTSTROUBLESHOOTING.8-7ENGINE.8-7CARBURETTOR - RADIATOR. 8-9ELECTRICAL SYSTEM.8-10BATTERY - BRAKES.8-11CHASSIS.8-12WIRING DIAGRAM.8-19ELECTRICAL SYSTEMINSPECTION.8-22BATTERY RECHARGINGINSPECTION - REGULATOR -GENERATOR -SPARK PLUGS.8-22CARBURATION -EXHAUST VALVES CONTROLMOTOR - EXHAUST VALVESPHASE CONTROL.8-28THROTTLE SENSOR - ELECTRONIC REV COUNTER -NEUTRAL SWITCH ANDLATERAL STANDSWITCH INSPECTION.8-28CABLE, WIRE, HOSEROUTING PASSAGE ANDFASTENING.8-29COOLING CIRCUIT.8-32MIXER OIL HOSE ROUTING.8-33CARBURETTORS AIRCIRCUIT.8-34FUEL HOSE ROUTING.8-35SPECIAL TOOLS.8-37TIGHTENING TORQUES.8-41TECHNICALSPECIFICATIONS.8-50.
INFORMACIONES PARA LASREPARACIONESINDICEBUSQUEDA DE LASAVERIAS.8-13MOTOR.8-13CARBURADOR - RADIADOR. 8-15INSTALACION ELECTRICA.8-16BATERIA - FRENOS.8-17CHASIS.8-18ESQUEMA ELECTRICO.8-19CONTROL DE LAINSTALACION ELECTRICA.8-22CONTROL DE LA RECARGADE LA BATERIA - REGULADOR -GENERADOR - BUJIAS. 8-22CABURACION - MOTOR DE CONTROL DE LAS VALVULAS EN EL ESCAPE -CONTROL FASE VALVULAS.
8-26SENSOR DEL GAS CUENTARREVOLUCIONES ELECTRONICO - CONTROL DEL FUNCIONAMIENTO DELINTERRUPTOR DEL PUNTO 8 MUERTO E INTERRUPTORDEL CABALLETE LATERAL. 8-28RECORRIDO, PASO YFIJACIONES DEL CABLEO -CABLES - TUBOS.8-29CIRCUITO DEREFRIGERACION.8-32TUBOS DEL CIRCUITO DELACEITE DEL MEZCLADOR. 8-33CIRCUITO DEL AIRE DELOS CARBURADORES.8-34TUBOS DEL COMBUSTIBLE. 8-35HERRAMIENTASESPECIALES.8-37PARES DE APRIETE.8-43CARACTERISTICASTECNICAS.8-55.
8 - 7 MSERVICING INFORMATIONTROUBLESHOOTINGENGINEComplaintSymptom and possible causesRemedyEngine will not start,Compression too lowor is hard to start1. SERVICING INFORMATION M 8 - 8ComplaintSymptom and possible causesRemedySlipping clutch1. Clutch control out of adjustment or loss of play.Adjust.2.Weakened clutch springs.Replace.3.Worn or distorted pressure plate.Replace.4.Distorted clutch plates, driven and drive.Replace.Dragging clutch1. Clutch control out of adjustment or too much play.Adjust.2.Some clutch springs weakened while others are not.Replace.3.Distorted pressure plate or clutch plates.Replace.Transmission will1. Broken gearshift cam.Replace.not shift2. Distorted gearshift forks.Replace.Transmission will1.
Broken return spring on gearshift fork shaft.Replace.not shift back2. Gearshift fork shafts are rubbing or sticky.Repair or replace.Transmission jumps1. Worn shifting gears on drive shaft or countershaft.Replace.ou of gear2. Distorted or worn gearshift forks.Replace.3.Weakened stopper spring on gearshift stopper.Replace.Engine idles1.
Spark plug gap too wide.Adjust.poorly2. Defective ignition coil.Replace.3.Defective ignition system.Repair or replace.4.Float-chamber fuel level out of adjustment incarburettor.Adjust.5.Clogged jets.Clean.Engine runs1. Spark plug gap too narrow.Adjust.poorly in2. Clogged jets.Clean.high-speed range3. Defective ignition coil.Replace.4.Defective ignition system.Repair or replace.5.Float-chamber fuel level too low.Adjust.6.Clogged air cleaner element.Clean.7.Clogged fuel pipe, resulting in inadequate fuelsupply to carburettor.Clean and refuel.8.Exaust valve control out of adjustment.Adjust.9.Defective exhaust valve control unit, actuator orexhaust valve.Replace.Dirty or heavy1. Oil pump out of adjustment.Adjust.exhaust smoke2.
Damaged or worn crankshaft oil seal.Replace.Engine lacks1. Worn piston rings or cylinder.Replace.power2. Spark plug gap incorrect or defective ignition system.Adjust or replace.3.Clogged jets in carburettors.Clean.4.Float-chamber fuel level out of adjustment.Adjust.5.Clogged air cleaner element.Clean.6.Imbalance of the carburettors.Adjust.7.Sucking air from intake pipe.Retighten or replace.8.Supplying too much engine oil.Adjust oil pump.Engine overheats1. Heavy carbon deposit on piston crown.Clean.2.Not enough oil supply.Adjust oil pump.3.Defective oil pump or clogged oil lines.Replace or clean.4.Fuel level too low in float chambers.Adjust.5.Sucking air from intake pipes.Retighten or replace.6.Using incorrect engine oil.Use prescribed oil.7.Defective cooling system.See radiator section.
8 - 9 MSERVICING INFORMATIONCARBURETTORComplaintSymptom and possible causesRemedyTrouble with starting1. Starter jet is clogged.Clean.2.Starter pipe is clogged.Clean.3.Air leaking from a joint between starter bodyand carburettor.Check and retighten.4.Starter plunger is not operating properly.Repair.Idling or low-speed1. Pilot jet is clogged or loose.Check and clean.trouble2. Air leaking from carburettor's S.I.P.C. Hose or starter.Check.3.Pilot outlet or by-pass is clogged.Check and clean.4.Starter plunger is not fully closed.Check and adjust.5.Imbalance of carburetors.Adjust the carburettors.Mediumor high-1. Main jet is clogged.Check and clean.speed trouble2. Jet needle is clogged.Check and clean.3.Throttle valve is not operating properly.Check throttle valvefor operation.4.Filter is clogged.Check and clean.Overflow and fuel1.
Needle valve is worn or damaged.Replace.level fluctuations2. Float is not working properly.Check and adjust.3.Foreign matter has adhered to needle valve.Clean.4.Fuel level is too high or low.Adjust float height.5.Clogged carburettor air vent pipe.Clean.6.Spring in needle valve is broken.Replace.RADIATORComplaintSymptom and possible causesRemedyEngine overheats1. Not enough cooling water.Add.2.Radiator core is clogged with dirt or trashes.Clean.3.Defective thermostat, stuck in closed position.Replace.4.Clogged water passages.Clean.5.Air trapped in the cooling circuit.Bleed out air.6.Defective water pump.Replace.7.Incorrect cooling water used.Change coolant.Engine overcools1. Defective thermostat, stuck in full-open position.Replace.2.Extremely cold weather.Put on the radiatorcover. SERVICING INFORMATION M 8 - 12CHASSISComplaintSymptom and possible causesRemedyHeavy steering1. Steering stem nut overtightened.Adjust.2.Broken bearing in steering stem.Replace.3.Distorted steering stem.Replace.4.Not enough pressure in tyres.Adjust.Wobbly handle1.
Loss of balance between right and left front forks.Adjust.2.Distorted front fork.Replace.3.Distorted front axle or crooked tyre.Replace.Wobbly front wheel1. Distorted wheel rim.Replace.2.Worn-down front wheel bearings.Replace.3.Defective or incorrect tyre.Replace.4.Loose nut on axle.Retighten.5.Incorrect front fork oil.Adjust.Front suspension1. Weakened springs.Replace.too soft2. Not enough fork oil.Refill.Front suspension1. Fork oil too viscous.Replace.too stiff2. Too much fork oil.Drain excess oil.Noisy front1. Not enough fork oil.Refill.suspension2.
Loosen nuts on suspension.Retighten.Wobbly rear wheel1. Distorted wheel rim.Replace.2.Worn-down rear wheel bearings orswingarm bearings.Replace.3.Defective or incorrect tyre.Replace.4.Worn swingarm and rear cushion related bearings.Replace.5.Loose nuts or bolts on rear suspension.Retighten.Rear suspension1. Weakened shock absorber spring.Replace.too soft2. Rear suspension adjuster improperly set.Adjust.3.Oil leakage of shock absorber.Replace.Rear suspension1. Rear suspension adjuster improperly set.Adjust.too stiff2.
Shock absorber shaft bent.Replace.3.Swingarm bent.Replace.4.Worn swingarm and rear cushion related bearings.Replace.Noisy rear suspension1. Loose nuts or bolts on rear suspension.Retighten.2.Worn swingarm and rear cushion related bearings.Replace.
With engine off and pick-up disconnectedThird inspection(pick-up)– Inspection three-wayTester indication =pick-up connector20 - 200 Ωnear fuses– Tester on Ω– Inspect from Whitecable to Brown cableWith engine off and pick-up disconnectedFourth inspection(pick-up)– Inspection three-wayTester indication =pick-up connector20 – 200 Ωnear fuses– Tester on Ω– Inspect from Whitecable to Red cableWith engine off and C.D.I. Unit disconnectedFifth inspection (C.D.I.)– Inspection four-wayTester indication =C.D.I.
Connector0,1 – ‘ (infinite)– Tester on K Ω– Inspect fromWhite/Black cable toWhite/Blue cableSixth inspection (C.D.I.)– Inspect fromTester indication =White/Black cable to0,1 – ‘ (infinite)Yellow/Black cableSeventh inspection(C.D.I.)– Inspection three-wayC.D.I. Connector– Tester on K Ω– Rotation inspectionIndication tester =of cables:Brown/White and1.016 Ω ± 5%Red/WhiteRed/White and506 Ω ± 5%Black/WhiteBrown/White and509 Ω ± 5%Black/WhiteWith engine onEighth inspection– Lack of spark inTester indication =lower cylinder0 Ω– Disconnect the three-way connector ofthe rev counter andcheck spark– Tester on k Ω– Inspect fromWhite/Purple cable toLight Blue/White cable. SERVICING INFORMATION M 8 - 50TECHNICAL SPECIFICATIONSCYLINDER - PISTON - PISTON RINGUnit: mmItemStandardLimitPiston to cylinder clearance0,055- 0,0710,120Cylinder bore56,000- 56,023Nicks or scratchesPiston diameter55,936- 55,96155,880Measure at 19 mm from the skirt endCylinder distortion–0,05Cylinder head distortion–0,05Piston ring free1stTApprox. 5,04,0end gap2ndTApprox. 8 - 51 MSERVICING INFORMATIONTHERMOSTAT - RADIATORItemStandardLimitThermostat valve opening50 ± 2°C–temperatureThermostat valve liftOver 7 mm at 65°C–Radiator cap valve110 kPa (1,1 kg/cm 2)–opening pressureTRANSMISSIONItemStandardLimitPrimary reduction ratio2,565 (59/23)–Final reduction ratio3,071 (43/14)–Gear ratiosLow2,454 (27/11)–2nd1,625 (26/16)–3rd1,235 (21/17)–4th1,045 (23/22)–5th0,916 (22/24)–Top0,840 (21/25)–Shift fork to groove clearance0,1 - 0,30,5Shift fork groove widthNo. 24,0 - 4,1–No. 35,5 - 5,6–Shift fork thicknessNo.
23,8 - 3,9–No. 35,3 - 5,4–DRIVE CHAINItemStandardLimitDrive chainTypeD.I.D. 520 V6–Links No.110–20-pitch lenght304Drive chain slack25 - 30–. SERVICING INFORMATION M 8 - 52CARBURETTORItemStandardCatalysed versionCarburetor typeMIKUNI TM34SSBore size34 mmI.D. No.23D4Idle rpm1.300 ± 150 rpmFuel level7,1 ± 0,5 mmFloat height8 ± 1,0 mmMain jet(M.J.)L: # 270, R: # 280Jet needle(J.N.)6GH8 - 55 - 3Needle jet(N.J.)0 - 80 - 9Cut-away(C.A.)1,5 mmPilot jet(P.J.)# 27,5# 20By - pass(B.P.)0,6 mmPilot outlet(P.O.)0,6 mmValve seat(V.S.)2,5 mmStarter jet(G.S.)# 45Power jetNo. 1L: # 55, R: # 35No.
20,7 mmAir screw(A.S.)–Throttle cable play0,5 - 1 mmELECTRICALItemSpecificationIgnition timing10° B.T.D.C. At 1.300 rpmSpark plugStandard typeNGK BR9ECMUpper heatrange typeNGK BR8ECMLower heatrange typeNGK BR10ECMGap0,7 - 0,8 mmSpark performanceOver 8 mm at 1 atm.Ignition coil resistancePrimary0,17 - 0,5 Ω (B/Y - W/L)Secondary5 - 30 k Ω(Plug cap - Terminal)Generator coil resistance0,1 - 1 Ω (Y - Y)Magneto coil resistancePick-up20 - 200 Ω (Br - W)coil20 - 200 Ω (R - W)Generator no-load voltageMore than 49 V (AC) at 5.000 rpm (Y - Y)Regulated voltage13,0 - 15,5 V at 5.000 rpmWater temperature gauge50 Ω at 90 ÷95°Cresistance15 Ω at 120 ÷130°C.
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