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Author Topic: Tuono known problems/hints/tips.(V Twins 2002-2010)  (Read 114554 times)
Keef B
Posts: 2682

Fenland F*ckwit.

« on: May 01, 2012, 01:14:20 PM »


The Aprilia Tuono is the perfect bike,yes? Er,not quite actually,..... lookup
The following is a guide to well known Tuono problems and niggles.I'm not saying you WILL have problems,...I'm saying you MIGHT have problems.

Difficult to start?Could be the battery,solenoid,.............
Batteries.(Gen 1 and 2)
Those big 'ol V twin pistons need a good battery to heave them over.The standard YXT 12BS battery is a bit weak and can fail with monotonous regularity.The popular replacement is the TTZ14SBS.Despite the number on the battery code,it is not rated at 14v.It has,however,a better cranking capacity for cold starts.(220amp,compared to the std 110amp)The battery is physically larger than standard but altering the fixing bracket is all that is needed.Some owners have done away with the bracket and simply wedged the larger battery under the seat.
Starter solenoid.(Gen 1)
Aprilia,in their wisdom,fitted a puny 50amp rated solenoid to early Gen 1 bikes.The internal contacts can burn out and fail.The later bikes got a 150amp rated solenoid for more reliable starting.Its a generic item made by Hitachi and often found on other makes of bikes,e.g Yamaha R1.
Aprilia part no.8112927
Yamaha part no.3UF-81940-00-00.

Sprag clutch.(Gen 1)
Starter sprag clutches can get a hard time,...especially if the battery is weak.If the bike sounds like a sack of spanners on start up,there is a good chance the sprag is on the way out.They are not cheap at around £200 and can be a little daunting to fit for the amatuer mechanic.A good dealer/service centre could do the job in around 3hrs.

Battery charging problems.(Gen 1 and early Gen 2)
As you may have realised,a good battery is vital to reliable starting.The easiest way to check the charging is to start the bike and rev it to 4000rpm.With a multimeter check the voltage at the battery terminals.You should see around 14.5v dc.Here are a few known problem area's on the charging system,...

Brown connectors.
Follow the lead away from the alternator casing and find a 3 pin brown connector.Pull the connector apart to inspect the terminals.They can burn out and reduce the amount of charge going to the battery.Some early bikes have another connector further up the wiring loom,so check that one as well.The simple cure is to cut the brown connectors off and fit through crimp connectors.The wiring can be very tight,so some extra wiring might be involved.
A good 'how to' guide can be found here,
Another connector to keep an eye on is the white barrel shaped item to the regulator.

Alternator stator.(Early Gen 2)
A few bikes have suffered from burnt out stators.New units from Aprilia cost around £300 but pattern copies can be bought for £114 from mail order specialists like Wemoto.
Stators can also be rewound and its a good idea to have it done with a thicker copper wire and less coils.This should,in theory,reduce heat build up.
It is believed the cause of the burn out can be traced to the super strong magnets in the rotor.There is/was an improved roror available.Its had about 2mm skimmed off the diametre to give a larger air gap and reduce the effects of the magnets.

Other random problems,....

Fogging clocks.(Gen 2)
Moisture can form in the clocks and mist up the display.Replacement clocks could be fitted,but several people have made successful repairs.The repairs involve removing the unit from the bike and splitting open the body.The lens is coated with a anti fogging solution,(sold at watersport shops) and resealed with silicone sealer.
Another cure is to ventilate the clock body.This can be a tricky job as it involves completely pulling the clocks apart and drilling holes in the body.There some good 'how to' write ups on the internet,if you want to have a go.

Sidestands.(Gen 1 and 2)
The stand fitted to European Aprilia's is not the best.Its too short and too close to the bike,which means you have to be very carefull when parking up on uneven ground.The bike could easily topple over.The USA and Canada get a far sturdier item that is designed to hold up the bike,rider and pillion.

US stands often come up on US Ebay,...although the price of them has risen recently.Another source is a 'wanted' ad on the AF1 site.Expect to pay around £100 for a good one.
N.B,the US stand will not work with a standard Euro bracket,so make sure you get a stand/bracket complete.Some Gen 1 US stands have an extra lug on the bracket.This can be cut off to suit the Euro bikes.
Alternatively,there is the 'Bubsewoo' stand.These were made by an RSV enthusiast and sold via various Aprilia websites and Ebay.These work well,although there have been one or two cases of them snapping.The other downside is that they dont appear for sale very often.
Another option is the stand from the '06 Honda Fireblade.These bolt straight on using the standard Aprilia bracket.
These can be ordered from a Honda dealer and cost about £65.Part number is 50530-MEL-000.
Not many secondhand ones around,but they do come up on Ebay Germany.
**Hot News**
Apparently the sidestand from the Honda Super Blackbird,(CBR1100XX) will also fit.All you need to do is drill a new hole for the switch to locate.AFAIK,all Blackbird stands are the same.

Suspension linkage bearings.(Gen 1 and 2)

At some point,Aprilia seem to have forgotten where the tub of grease has gone.The suspension linkage is notorious for running dry and the bearings seizing.(items no.3 in diagram)Ultimately the linkage could snap in extreme cases.The service schedule says the bearings should be greased every two years or 25K miles,but this is often overlooked.(Probably because you have to take the exhaust off to get to the dog bone.)
Its a good idea to have the linkage checked and lubed annually.Makes a nice little job to do in the winter.

Rear Brake.(Gen1 and 2)
Sooner or later the Tuono's rear brake will stop working.Poor positioning of the master cylinder and heat from the engine destroys the fluid making the rear brake useless.Regular bleeding of the brake fluid helps but its only a temporary fix.Aprilia know about it and issued a service bulletin to dealers to allow more time for bleeding the rear brake.They also recommend unbolting the rear caliper and hanging it off the frame while the system is bled.
If you dont want to be constantly bleeding brakes,the only reliable cure is to fit a set of Aprilia Performance rearsets.These move the master cylinder up and away from the engine.
Another fix is to fit a master cylinder from a Ducati 1098/848.A longer brake line may be required.
« Last Edit: March 24, 2015, 06:55:18 PM by Keef B » Logged

25yr old trapped in a 55yr old body.
Step away from the magnets.
« Reply #1 on: May 01, 2012, 05:29:18 PM »

Another nice one KB. happy88
« Reply #2 on: October 26, 2012, 11:48:36 AM »

Some brilliant stuff you have put on this site Keef B very very helpful happy88 happy88, so thanks for taking the time to put all this together well impressive...
« Last Edit: October 26, 2012, 11:49:06 AM by mpgscott » Logged
Master Fud
Posts: 4487


« Reply #3 on: October 26, 2012, 12:54:01 PM »

 clapper   clapper   clapper

Superb Keith.

Well done mate.  happy88
Posts: 197

« Reply #4 on: November 01, 2012, 08:25:14 PM »

As a new owner, this information will come in handy. I have formatted it into a PDF and printed it out for when internet access is lacking. I thought I'd share it as it might be useful to others. Let me know if this is not ok and I'll remove it.

Good work Keith  happy88

Posts: 378

« Reply #5 on: November 02, 2012, 04:20:21 PM »

 bop17 bop17 bop17 brilliant guide have used this info in my recent serch for "the right bike " , which i have now found and will post pictures of my new pride and joy when ive collected it . thanks very useful !!!

oh, bollox
Mega Fud
Posts: 1697

« Reply #6 on: May 02, 2014, 02:40:26 PM »

Very useful indeed. I'll be on the lookout for one of those US spec stands.
Mega Fud
Posts: 2081

« Reply #7 on: May 02, 2014, 04:38:40 PM »

Very useful indeed. I'll be on the lookout for one of those US spec stands.

There is one for sale on here...


Proper Fanny
Posts: 5513

Should know better

« Reply #8 on: May 02, 2014, 06:33:23 PM »

Baby Fud
Posts: 4

« Reply #9 on: July 11, 2014, 11:01:39 AM »

great article keef b. having eventually found and bought a gen 1 tuono factory I was disappointed with the side stand to say the least, especially as
I do a lot of touring and find it easier to mount the bike standing on the left foot peg when I`ve a large tail pack on.
this is not realy possible with the o.e stand, so I`m on the look out for the us version.
thanks again for your efforts
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