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2007 Tuono rebuild...ish

gitter

gitter

Buff Midget
Joined
Oct 17, 2006
Location
Napa
Moto(s)
22 Tuono Factory // 07 Tuono // 2020 speed triple rs (for sale)
Name
Gitter
Picked up a high milage / non running 2007 Tuono 1000R back in October. Been slowly going through it. Figured I would document here because who doesn't love pictures.

Picked it up from a guy over in Santa Rosa, Second owner. He bought it with 8000 miles on it and sold it to me with 57,000 on the clock. It would crank but wouldn't start. A bit rough in spots but overall not bad.

Decently set up. Akra slip ons, map 2, factory rear shock.

Day I brought it home
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Checked the diagnostics in the dash and it was throwing a code for the Crank sensor (P code 0339 / A code 12). Previous owner said he put a new one in so I kept digging around. Remembered reading that when the stator goes out on the second gen rotax it will do wonky things to the ecu. Unplugged the stator and it cranked over and ran. Pulled the side cover and the stator was...crispy.

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Sourced a new rick's stator and reg/rec from AF1, hard wired to get rid of the brown connector and everything went in as planned.

Took it around the block to test it, almost immediately threw a code for the o2 sensor (P code 0130 / A code 46). Also noticed the fork seals were both leaking aggressively.
 
Decided to tackle the seals first. Impulse bought a set of factory forks on ebay.
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Broke them down, cleaned everything, fresh seals and 5w fresh oil.
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Also figured out that in a pinch a bike stand can be used instead of a fork vice
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Got the forks back together, repacked the head bearings with grease, and got everything buttoned back up.

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Got back to trying to sort out the o2 sensor code. Wouldnt throw the code when the bike was idling in the garage but as soon as I rode away I would get about 20 feet and the code would pop back up. Sourced a new o2 sensor from British company as AF1 didn't stock replacements anymore. Got it installed, still throwing the code. Figured there was a short in the harness somewhere. Dug into the harness, couldn't find anything. Rechecked the plug, saw an odd zip tie around the harness side of the plug for the o2 sensor. Snipped it off and out fell the signal wire for the o2 sensor.

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Re-pinned the plug and code disappeared.
 
Decided to tackle the front brakes next as they needed attention. Calipers were pretty grimy and pads felt like they were soaked in oil.

Cleaned up the calipers, just took some time and an old toothbrush. Didnt get all of it, but got most of it and enough to make sure the pistons were still functioning as they should.
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Fresh EBC HH pads went in along with a RCS 19 radial MC. Huge improvement over stock as far as braking feel.
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Tires needed replacing. Went with a set of Dunlop Q5s'. (yes the rear tire is mounted backwards in the picture. after much head scratching and post on barf I took it back and got it swapped)
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Got them mounted and took it for a test drive. Need to dial in tire pressure. If anyone has any suggestions I'm all ears.
Currently how the bike is sitting:
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will update as I get more done
 
Those Rotax motors are bullet proof. I rode the paint off a 2003 Capanord with a detuned version of the same motor.
 
Looks beautiful! Nicely done on the rebuild/refresh.

I bought a friend's '07.5 (20k miles when it came to me) and had a mechanic friend go through it, because I'm not especially mechanical (or patient). Cleaned up a bunch of niggles and it's been a hoot...until recently. It won't start, with a new/charged battery, unless it's on the 'Tender. If not, I just get "rar-rar-rur-rur-bleh". My buddy thinks it's likely the starter. I hope it's that simple!
 
Thank you! It was a fun refresh, I'm debating selling it, its listed but the longer it takes to sell the more I get to ride it.

I'm curious what's causing your no start issue. Was the brown connector snipped and hard wired in? Out of curiosity, if you unplug the Stator / reg/rec, will it crank over and start?
 
Excellent thread, Gitter.
I've stood in that very garage!
I bought my SV650 from you. It's still running strong. (It's slightly over sprung with that ZX10 shock, but it's fine on the track)
We never did circle back for that lunch we discussed. Are you still up for it?
 
I absolutely still am up for it! I’m happy to hear the sv is still around. I miss that bike sometimes
 
FoolishMortal said:
Looks beautiful! Nicely done on the rebuild/refresh.

I bought a friend's '07.5 (20k miles when it came to me) and had a mechanic friend go through it, because I'm not especially mechanical (or patient). Cleaned up a bunch of niggles and it's been a hoot...until recently. It won't start, with a new/charged battery, unless it's on the 'Tender. If not, I just get "rar-rar-rur-rur-bleh". My buddy thinks it's likely the starter. I hope it's that simple!
Click to expand...
To add to my other question of if it will start and run with the stator and reg/rec unplugged, is it throwing any codes?
 
gitter said:
To add to my other question of if it will start and run with the stator and reg/rec unplugged, is it throwing any codes?
Click to expand...
I might be able to get into it this weekend, but I'm no mechanic. It will take a lot of YT "research" to figure out what to do and where. I really doubt that the "brown wire" fix was done, though, so maybe that's a thing.

It cranks a few times, dies, and the display shows "service". That's really all I know, other than that the battery is good.
 
ok cool, service light is actually good, it gives you a direction. With the key in the on position, on the left hand switch gear, switch all the way down to mode (below trip 1 and trip 2), long press the button on the front of that same left hand switch gear ( its on the bottom front) once the menu pops up, go to diagnostics, short press on that same button to cycle through options, long press to select. Once you're in the diagnostics menu, enter the code 13432 (short press to cycle through numbers, long press to go to next number in the sequence), that should give you whatever code is tripping the service light and will give you some direction as to what is causing your issue.

Also, when you crank it over, does it crank, fire off once and then die? or does it just crank thats it?
 
Way back when there was a bike show at the San Mateo fairgrounds I got a test ride on the first generation Tuano. I had no idea the anticipation for the bikes introduction and lucked out with th test ride. I've been a fan ever since! The seating position and engine are perfect!
 
If I didn't already own a TV4F, I'd be all over that. IMHO Tuonos are forever bikes.
 
OldMadBrit said:
If I didn't already own a TV4F, I'd be all over that. IMHO Tuonos are forever bikes.
Click to expand...
I sold my ‘16 TV4RR for the speed triple rs I have now. I’ve debated switching back and getting a factory but I do enjoy the 1050 triple.
 
Come back to the dark side :cool: :p

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There's a 2018 Factory for sale that I've been eyeing :cry
 
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