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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  • Anonymous Mar 11, 2014

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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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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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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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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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