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Thread: How to convert a 98-03 Mille to a Tuono

  1. #1
    apriliaforum expert BrummyMax's Avatar
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    How to convert a 98-03 Mille to a Tuono

    You need these parts:


    Relay and fusebox plastic shrouds
    Part numbers 1 & 6
    AP8168058
    AP8168059


    Front indicator mounts and countersunk bolts
    Part numbers 9, 10 & 2 x 11

    AP8134897
    AP8134896
    2 x AP8152566


    Front brake master cylinder U-bolt
    Part number 6
    AP8168501


    Clutch master cylinder U-bolt
    Part number 8
    AP8168217


    Bellypan brackets
    Part numbers 7 & 8
    AP8134894
    AP8134895


    Coil cover bolts
    4 x part number 12
    4 x AP8134923


    Radiator end spacers
    4 x part number 16
    4 x AP8152436

    You will also need to get longer brake lines. Make sure you get the correct angle banjo fittings for your calipers. If you have the 4 pad Mille R calipers then standard Tuono lines will have the wrong banjo. The original 2002 Tuono limited had the four pad calipers. All other Tuonos have either 4 pad radial calipers or 2 pad standard calipers.

    You also need a longer clutch line.

    There are various options for top yoke, bar and risers. If you get standard ones, be sure to get the correct top yoke for your forks. Ohlins forks have 51mm fork clamps and Showa forks have 53mm fork clamps. Some people have used 1mm aluminium sheet bent as a spacer for the Ohlins forks with the Showa top yoke. LSL and ABM also do top yoke kits with risers. The streetfighter store sells kits that include top yoke, risers, bars and longer brake+clutch lines. See here: Aprilia yoke kits. Be aware that their brake and clutch lines are not long enough for standard Tuono risers. On their kits, the risers are lower. When swapping top yokes, move the Mille wiring loom from the outside of the forks to the inside. You also need to move the air temp sensor from the left hand Mille air tube to the left hand front relay shroud. There is a threaded hole that it screws into.

    The brackets that hold the clutch fluid reservoir and front brake reservoir are slightly different on the Tuono. You can buy the genuine Tuono ones or slightly bend the existing Mille ones.

    You will need a pair of mirrors. 2006+ Tuono mirrors also work well.

    You can buy standard Tuono crash bungs or the R&G offering parts. The R&G ones hold up better in a crash.

    You also need front fairing, screen, bellypan, coil covers, coolant bottle cover, radiator ends and air scoops/intakes. It is possible to cut down the Mille bellypan and front fairing. If you want a genuine tail end on your Tuono you need an 03 Mille or 02-05 Tuono rear plastic. If you are converting a 98-00 Mille and are changing to a genuine Tuono rear plastic, then you also need the 01-03 Mille taillight without the plastic shroud or an 02-05 Tuono tailight. They are the same. If you are changing to a genuine Tuono front fairing, then you will also need a Tuono screen. It is shorter than the Mille screen and only has 6 bolts, not 8. The radiator ends bolt on through 4 plastic spacers. You can either buy the genuine spacers or find an alternative locally.

    The standard Tuono front subframe has a C shaped bracket welded to it. This reinforces the tube that comes from the headstock. The Mille does not need this because the air tubes and fairing partly support the front fairing, subframe, clocks and headlight. Here is a Mille subframe that I had modified:
    Last edited by BrummyMax; 05-27-2010 at 05:42 AM.

  2. #2
    apriliaforum expert BrummyMax's Avatar
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    This is my conversion from what I started with to what the bike became.





  3. #3
    apriliaforum Member MD RSV's Avatar
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    Nice writeup Max. Need to touch on the fairing bracket mod.

  4. #4
    apriliaforum expert BrummyMax's Avatar
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    Quote Originally Posted by MD RSV View Post
    Nice writeup Max. Need to touch on the fairing bracket mod.
    Yep. I also forgot radiator ends with the little plastic spacers and Tuono screens

    I will edit it.

    Hank, make this a sticky because I get many PM's asking about this so am forever repeating myself!

  5. #5
    apriliaforum expert AliPisha's Avatar
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    Brilliant write up Max

  6. #6
    apriliaforum prov-nov yogurt's Avatar
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    Dont forget this one stated life as a mille!
    me holding my exhausts!!!!

  7. #7
    apriliaforum expert AliPisha's Avatar
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    Feckin hell do you ever ride that?? it looks immaculate!!! Feckin orrible but immaculate

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    apriliaforum expert hairy's Avatar
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    and heres me thinking u just stick an pair of tuono bars onto it,good write up dude,but i would have kept the yellow paint sceme
    the one and only original hairy,any attempts at copying will fail ,
    cause araihead stuck his finger up a woodpeckers hole,

    and the woodpecker said god bless ur soul,

    pull it out
    pull it out

  9. #9
    apriliaforum expert Batfastard's Avatar
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    Wink

    Quote Originally Posted by yogurt View Post
    Dont forget this one stated life as a mille!
    Are you the Yog from Goxhill?

  10. #10
    apriliaforum expert FTM's Avatar
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    Quote Originally Posted by Batfastard View Post
    Are you the Yog from Goxhill?
    With the Gixxer streetfighter?
    FUCK THE MAGS


    Never live the same day twice. (My wife nearly pissed her self laughing when she read my signature line, because she reckons she has never met anyone in the whole of her life who hates change more than me) She does have a point .

  11. #11
    apriliaforum prov-nov yogurt's Avatar
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    yes mate
    me holding my exhausts!!!!

  12. #12
    apriliaforum Member
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    tell us and what items we need to convert it from tuono to mille

  13. #13
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    I want to do the same to mine, change from Tuono to Mille.

    I am done with the streets and keeping it on the track. Any advice?

  14. #14
    apriliaforum Junkie AndyBev's Avatar
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    I have a mille top yoke which i will swap for a tuono one if you like?
    Tuonoless.

  15. #15
    apriliaforum expert BrummyMax's Avatar
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    Quote Originally Posted by tattsailor View Post
    I want to do the same to mine, change from Tuono to Mille.

    I am done with the streets and keeping it on the track. Any advice?
    Well I can supply you with most of what you need. I will swap for some of your parts if you want. The only things you will need to find elsewhere are airscoops (left + right, inner + outer), screen, top yoke and clip ons.

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