Question about 2008 Aprilia Tuono 1000 R Factory

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Engine siezed ?

I recently purchased a 2005 Tuono Factory that had been dropped,only minor cosmetic damage,gear lever was bent.Engine would'nt start, removed spark plugs and tried to turn engine over by hand but can't get engine to turn over just a clunk noise when i try and no movement,also hard to get into second gear.
My thoughts are that something was bent inside gear box and gears are jammed??? what is the possability of this ?

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Could be a broken tooth on a gear that just hasnt broke yet, or a shift fork may be bent jammin things up. Number of things coulda caused it, but your gonna need to split the cases to fix it either way. Good Luck to ya.



Posted on Nov 15, 2008

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1 Answer

Wont go in 2nd gear

If it will go into all other gears but not second, the transmission may have damage like a bent shift fork, damaged gears and/or shift drum. If the bike has been raced or accelerated hard and gear shifts have been missed, it most likely has transmission damage and the engine will have to come out and be torn down in order to repair. If the bike was hopping in and out of second gear before it stopped going into second, the transmission is most likely damaged.
One more thing to try is to take the shift lever and push momentarily down or up on the lever and see if it smoothly returns to its original center position. If it does return to the center position the lever is not sticking and ir it does not return to center position then the shift lever is sticking and that will keep the trans from up or down shifting.

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My 2005 Yamaha R6 Is having problems with Shifting. Every time I up shift I have to press the lever down about an inch in order to shift up again or it wont shift at all. Other then that It is shifting...

Chances are you have some bent shift forks - happens a lot when the transmission gets mauled or the bike has been stunted with the front end up in the air a lot. The transmission basically starves for oil and the components start breaking down. Your going to need to drop the engine out of the bike to service any part of the transmission besides the clutch. The engine needs to be split in half to do so.

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2005 Aprilia Tuono R Started after a few tries but only for a couple seconds, i gave it a little gas and it made a "clunk" and then would not start again. Has full charge on the battery and makes...

Hi, Restlessness and the usual suspects are:
1. Ignition Switch not in the "ON" position.
2. Engine Run Switch in the "OFF" position.
3. Discharged battery, check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
4. Bank angle sensor tripped and ignition/light key switch not cycled to the "OFF" position and then back to the "ON" position.
5. Security alarm needs a reset.
6. Starter control circuit, relay, or solenoid faulty.
7. Electric starter shaft pinion gear is not engaging or over-running starter clutch slipping.
For more information about your issue, please visit the websites below. Good luck and have nice a day.
DOWNLOAD 2005 Aprilia Tuono 1000

Feb 06, 2011 | 2005 Aprilia Tuono 1000 R

1 Answer

Have recently replaced the Clutch Kit on a Peugeot 206 model is 2005. The car is running but goes into third gear instead of first gear at times. It seems as if the linkages are not pushing far enough. Can...

Check to see that none of the gear linkages have been bent or misaligned. Check for wear in the gear linkage joints and also in the gear lever attachment point.

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Hi i have an 02 Honda cb250 that i cant seem to get the gear selector to operate. All was well until i bent the lever a bit to suit my foot as it had been bent purposely to suit the smaller previous owners...

The bike has a bent shift for or two. The engine will need to come out of the bike and get a complete teardown. A shift fork moves a "slider gear" left and right on a shaft. Both sides of the slider gear have "dogs" that engage into the side of an adjacent gear. This is how the different gears are engaged. A bent fork will not slide properly or engage properly. It is a costly repair. Note that if the inspection reveals a broken gear tooth, the smooth shaft that the shift fork slides on could be bent, and/or the gear shafts could be bent as well.
Can I get a “very helpful” rating on this answer?

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Aug 22, 2009 | Honda CB 250 Motorcycles

1 Answer

1st gear issues

How do I put this? Yes, you have a bent shift fork. And, yes, they can get bent in a fall, a dump, a drop or whatever terminology is used. The fork engages into a collar on a gear that slides left and right, (slider gear). Large "pins" called "dogs" are cast into the side of the gear. The dogs engage into holes in the side of the gear you are shifting into. Question: What happens if the bike drops on the clutch side and the shift lever is forced down, moving the slider gear to engage first gear even though the holes in the side of first gear are not lined up with the dogs on the slider gear? "You get a bent shift fork" is the correct answer. The force of the shifter lever moving the shift fork into the solid parts of first gear, (not lining up with the holes), is easily great enough to bend a fork. That pressure has got to go somewhere.

The repair means removal of the engine and a complete tear down of the engine/gearbox. The replacement of the bad fork is a given. But I suggest you do some preventative maintenance now, while the engine is apart anyway. Replace the sprocket shaft left bearing and seal, both crankshaft bearings and seals, shift shaft seal and the water pump seals. These are pretty low cost items and replacing them will mean you have pretty much rebuilt the engine. Have the dealer check the shift shaft to be sure it does not now have a bend in it.

Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock.

Go to this site and you can download a free PDF service manual. Most of the manuals are in English but some are not. There is no way to be sure without doing the download. You can always delete it if in a foreign language.

By the way, you can click on an experts name and see that persons profile.
Best wishes, tombones49 Please top rate this solution. Thanks!

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1 Answer

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Hi There,
Kindly check if you do have sparks at the sparkplugs as you cran-start it.


Feb 01, 2009 | 2008 Aprilia Tuono 1000 R Factory

1 Answer

Clutch Lever

AND has a cheaper list price or did I dream that ?You can buy patern levers for much less than the Aprilia one. problem you may have is getting the little brass adjuster out of the old lever. For some strange reason it does not come with the lever. It is a bugger to remove and if you do not set it right then you can get clutch slip.,,

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my rev limiter is set at 11500rpm but in some gears it cuts in at 10000. this has only recently started and as my aprilia dealer has packed up i cant just pop it in. its causing havoc with my one wheeled action!!set it via the on board computer as per the manual matey.,,

Nov 10, 2008 | 2004 Aprilia Tuono 1000

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