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Aprilia · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, chain drive

Tuono 1000

Library entry covers 2003-2015

24 factory 30 guideline

Published source

aprilia Tuono 1000 workshop manual UK 8104982 (12/2005), 2.1.2 Scheduled maintenance chart pp.2-6, 2-7

Factory workshop manual. Covers RSV 1000 Tuono R workshop manual 8104982 (12/2005).

Open the source

54 items for a 2005 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2005 Aprilia Tuono 1000

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

On the road: every 625 mi

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain tension and lubrication. Factory: Every 1000 Km (625 mi)

Every 1,000 mi or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 1,250 mi

1 item

Check brake pads and discs

Brakes

Factory

Manual: Brake pad wear. Factory: Before each ride and every 2000 Km (1250 mi)

Every 3,000 mi or 12 months

4 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline

Every 3,125 mi

1 item

Inspect clutch plates and springs

Primary and gearbox

Factory

Manual: Clutch wear. Factory: Marked at 5,000 km (intensive racetrack use) column only

Every 4,000 mi or 12 months

2 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 6,000 mi or 12 months

4 items

Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,250 mi or 12 months

8 items

Change engine oil

Engine

Factory

Manual: Engine oil. Factory: Change; end of running-in 1,000 km (625 mi); every 5,000 km for intensive racetrack use
Inspect coolant hoses and clamps

Engine

Factory

Manual: Cooling system.
Replace oil filter

Engine

Factory

Manual: Engine oil filter. Factory: Change; every 5,000 km racetrack use
Synchronize throttle bodies

Fuel and air

Factory

Manual: Cylinders synchronization. Factory: Also at end of running-in
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Final drive (chain and chain sprockets).
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings and steering play.
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings.
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Bowden cables and controls.

Every 6,250 mi

1 item

Check gearbox oil level

Primary and gearbox

Factory

Manual: Gearbox. Factory: Every 10000 Km (6250 mi): check

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

1 item

Grease swingarm pivot

Rear suspension and frame

Guideline

Every 12,500 mi or 2 years

6 items

Check valve clearances (shim adjusted)

Engine

Factory

Manual: Valve clearance adjustment. Factory: Set or adjust; every 5,000 km racetrack use
Clean oil strainers / mesh screens

Engine

Factory

Manual: Engine oil filter (on oil tank). Factory: Clean
Replace spark plugs

Engine

Factory

Manual: Spark plug. Factory: Change; check at 10,000 km
Replace air filter element

Fuel and air

Factory

Manual: Air filter. Factory: Change; check at 10,000 km
Clean and grease rear suspension linkage

Rear suspension and frame

Factory

Manual: Rear suspension connecting rod bearings.
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear shock absorber.

Every 12,500 mi

2 items

Change fork oil

Front end

Factory

Manual: Front fork fluid. Factory: After the first 10000 Km (6250 mi), then every 20000 Km
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front fork oil seals. Factory: After the first 30000 Km (18650 mi), then every 20000 Km

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 24,000 mi or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

5 items

Replace coolant

Engine

Factory

Manual: Coolant. Factory: Change every 24 months
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Replace hydraulic clutch fluid

Primary and gearbox

Factory

Manual: Clutch fluid. Factory: Change every 24 months (12 months racetrack use)
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Factory

Manual: Brake fluid. Factory: Change every 24 months (12 months racetrack use)

Every 4 years

3 items

Replace fuel lines

Fuel and air

Factory

Manual: Fuel lines. Factory: Change every 4 years; check at 10,000 km
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.