Page 1 of 2 12 LastLast
Results 1 to 15 of 21

Thread: Futura Information/Repairs

  1. #1
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117

    Futura Information/Repairs

    Thought I would post a thread with useful links and information that can eventually be turned into a one-stop-shop sticky. How do we get something stickied btw?

    I’ve just been compiling this as I read the forum and fixed my bike. I'm sure it will help other people too.

    Anyway, if anybody else has useful information, or common mods that I didn’t include here, feel free to chime in. I’ll try to keep on top of this by editing my subsequent information posts, so everything can be at the top of the thread.

    Helpful links:
    ——————
    Futura information: http://www.apriliafutura.co.uk/v2/

    Falco information (same engine): http://home.comcast.net/~sl_mille/index.html

    Buy parts (AF1Racing): http://www.af1racing.com/store/Scripts/default.asp

    Disassembling stock connectors: http://www.apriliaforum.com/forums/s...ock-Connectors
    Servicing the forks: http://motardsardechois.free.fr/Page...%20anglais.pdf
    Removing the rear shock: http://www.apriliaforum.com/forums/s...service-manual

    TuneECU: http://www.tuneecu.com/TuneECU_En/index.html
    TuneECU cables: http://www.lonelec.co.uk/index.php?m...uneECU&x=0&y=0

    Manuals: http://www.apriliafutura.co.uk/v2/wo...p-manuals.html
    Wiring Diagram: http://www.cefs.co.uk/Aprilia/FuturaWiringDiagram.pdf
    Last edited by infrasoundxp; 10-27-2014 at 01:09 AM.

  2. #2
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117
    Tire size:
    ------------
    Front: 120/70/17
    Rear: 180/55/17



    Part Numbers:
    ———————

    Starter Solenoid:
    ----------------------
    OEM: AP8124636
    Ford: E9TZ-11450-5 (requires wire modification; see below)
    Motorcraft: SW1951C (requires wire modification; see below)
    Yamaha: Y-4KD-81940-00-00



    Battery:
    ----------
    Everstart (Walmart): ES12BS or ES-TX12
    Diehard: 44016 (12-BS)
    Yuasa: YTX12-BS
    Yuasa: YTZ14S (1/2" shorter than OE, but has more CCA capacity and Ah --RAS)
    MotoBatt: MBTX12U
    Shorai: LFX18A1-BS12 or LFX19A4-BS12


    Diode:
    ---------
    OEM: 1N4004 (1A, 400V)
    NTE Electronics: NTE116 (1A, 600V) (http://www.newark.com/nte-electronic...d=800000005456)


    Injection Relay:
    -------------------
    OEM: 895481
    Dorman: 84601


    Regulator/Rectifier:
    --------------------------
    Rick’s (OEM): 10-002 (http://ricksmotorsportelectrics.com/...RBcHJSU1QxMDAw)
    Rick’s (Mosfet): 10-002H (http://ricksmotorsportelectrics.com/...RBcHJSU1QxMDAw)
    Shindengen (Mosfet): FH020AA (http://www.roadstercycle.com)
    [UK] Electrex World (Mosfet): RR97 (http://www.electrexworld.co.uk/acatalog/RR97.html)


    Spark plug wires:
    -----------------------
    Magnecor: #2592 (http://www.alamomotorsports.com/Magn...g_aprilia.html)


    Spark plugs:
    -----------------
    NGK (OEM): DCPR9E
    NGK (Iridium): DCPR9EIX
    Denso (Iridium): IXU27

    Alternatives: http://www.sparkplug-crossreference..../NGK_PN/DCPR9E


    Vacuum Line Check (Anti-return) Valves:
    ------------------------------------------------------
    OEM:
    AP8104251
    Audi/VW:
    058-905-291k
    Last edited by infrasoundxp; 09-21-2014 at 01:42 PM.

  3. #3
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117
    Must-have repairs
    ————————

    These are repairs you should do before riding your bike (at least make sure you have them). These cause safely or reliability issues if left for later.


    SAFETY ISSUE: Full Metal Fuel Quick-Disconnect:
    ---------------------------------------------------------------------
    Your bike should have at least a metal right-angle connector because Aprilia recalled that part. However, you should also replace the straight connector with a full-metal version too. Without this modification, fuel can dump out on top of your hot engine and cause a fire.
    http://www.apriliafutura.co.uk/v2/wo...ification.html


    SAFETY ISSUE: Plugging the fuel pump plate:
    ---------------------------------------------------------------
    The fuel tank breather hose usually gets a crack in it from ethanol damage and time. Like the QD modification above, fuel can dump out causing a fire if this is not repaired. Plugging the fuel pump plate is the recommended course of action, but you can also buy another breather hose if you want to.

    Note: Some people have reported that their plate wasn’t drilled all the way through from the factory, so you might not need to do this repair.

    http://www.apriliaforum.com/forums/s...=1#post3514045


    Wiring mod for charging issues:
    ------------------------------------------
    The charging circuit from the R/R to the battery in the Futura wiring harness has small wires and a very circuitous route. This causes low voltage at the battery which can cause issues with charging. The wiring mod is an easy modification to increase the voltage at the battery eliminating the issue.

    http://www.apriliaforum.com/forums/s...harging-issues


    Repair bad crimp in forward wiring harness:
    ------------------------------------------------------------------------
    Repairing the bad crimp with solder and epoxy-filled heat shrink is best, but you should make sure you at least have a slit at the bottom of the thick tubing around the wiring harness so that water cannot fill up the inside.

    http://www.apriliaforum.com/forums/s...=1#post3311394
    http://www.apriliaforum.com/forums/s...ghlight=splice


    R/R wiring repair:
    --------------------------------------
    Some people have noted that just cleaning out the connectors at each oil change is also a viable solution instead of the normal solder/heatshrink repair. You can also buy waterproof connectors and replacement R/R’s from links inside the forum post below (second link).

    http://www.apriliafutura.co.uk/v2/wo...connector.html
    http://www.apriliaforum.com/forums/s...thout-pigtails
    Last edited by infrasoundxp; 02-17-2014 at 01:40 PM.

  4. #4
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117
    Other repairs:
    ————————

    Dash repair:
    -----------------
    Lots of good information for broken dashes in this thread: http://www.apriliaforum.com/forums/s...rd-dash-repair
    You can also buy replacement dashes, or send in your dash for repair here: http://www.moto-abruzzo.com/for-sale/


    Fuel pump bulkhead repair:
    ------------------------------------
    Ethanol can eat away at the epoxy in the fuel pump wiring bulkhead causing issues with the wiring. It is best to dig/drill out the plastic and epoxy, then solder the wires and re-epoxy with Caswell Fuel Tank Sealant.

    http://www.apriliaforum.com/forums/s...k-is-open-quot


    Vacuum line replacements:
    -----------------------------------
    The OE lines that came on the bike are clear nylon lines that don't hold up well after years of use. Most people have replaced theirs with high quality automotive vacuum lines. If you are having trouble routing the lines, refer to the post below.

    http://www.apriliaforum.com/forums/s...m-Line-Routing


    Starter motor repair:
    ---------------------------
    deefred has been kind enough to post a detailed writeup on how to disassemble, clean and reassemble your starter motor.

    http://www.apriliaforum.com/forums/s...assembly/page2


    King bearing repair:
    -------------------------
    Many people have seen corrosion inside the king bearing (rear axle). Some have even seen their bearing seize because of this. It's a pretty good idea of have this checked/re-greased periodically. More information in the posts below.

    http://www.apriliaforum.com/forums/s...earing-Batman!
    http://www.apriliaforum.com/forums/s...me-Maintenance


    Evoluzione Clutch Slave Bearing Repair:
    -------------------------------------------------------
    If you have an Evoluzione clutch slave (looks like the picture in the first link below), many forum members recommend adding a 1/4 plug inside the bearing in the bore of the slave (second link below). If you don't, then your clutch rod can get worn away and cause you to lose your clutch travel over time (third link).

    http://www.apriliaforum.com/forums/s...=1#post3566450
    http://www.apriliaforum.com/forums/s...&highlight=EVO
    http://www.apriliaforum.com/forums/showthread.php?192083-Mysterious-clutch-issues&p=2364948&viewfull=1#post2364948



    Steering Stop Repair:
    -------------------------------------------------------
    Sometimes the steering stops can get bent, or the additional rubber stopper that previous owners have added can deteriorate, causing the switch clusters on the handle bars to contact the tank (especially the horn switch). The nylon fuel tank can also expand from the ethanol that is added to gasoline nowadays. You can add a ziptie to each steering stop to give the added bit of room needed to fix this.

    http://www.apriliaforum.com/forums/s...tting-the-tank


    Rubber rear bag attachments:
    -------------------------------------------------------
    The rubber rear bag attachment has broken on many of our bikes. One easy solution to this is to replace the broken rubber piece with a 35mm o-ring and a zip-tie.

    http://www.apriliaforum.com/forums/s...=1#post3708117


    Vacumm check valve repair:
    ---------------------------------------
    There are three vacuum check valves in the vacuum systems on the Futura. One for each cylinder and one for the "slipper" clutch. If you engine runs on after closing the throttle, then it's possible that one of the vacuum check valves for one of the cylinders has developed a leak (See the post below). Audi/VW engines have check valves that are the same hose sizes as the Futura (see the parts section above).

    Note: the US version seems to be the only one with three check valves. The European bikes only have a check valve in between the cylinders plus the clutch check valve.

    http://www.apriliaforum.com/forums/showthread.php?274442-Egine-runs-on-when-throttle-closed-any-thoughts&p=3452843&viewfull=1#post3452843
    Last edited by infrasoundxp; 09-21-2014 at 03:14 PM.

  5. #5
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117
    Common mods:
    ———————
    See also: http://www.apriliafutura.co.uk/v2/wo...fications.html


    Cheaper Coils/wires:
    ----------------------------
    Aprilia coils are expensive and prone to failing a lot, especially with a bad/going bad battery. These mods replace the stock coils with much cheaper coils from different manufacturers.

    Japanese motorcycles - http://www.apriliaforum.com/forums/s...for-the-Futura
    European cars - http://www.apriliaforum.com/forums/s...g-from-the-USA

    CBR600 Coil Howto:
    http://www.apriliaforum.com/forums/s...utura-Tutorial


    Fuel Pump Regulator (FPR) Mod:
    --------------------------------------
    The fuel pump regulator static vacuum line is attached to atmosphere (the air box) from the factory. Many people have found that attaching the line to the manifold smooths out the throttle response in lower revs and increases fuel economy. For this mod, most people have attached the FPR to one of the sync lines coming off of the throttle bodies.

    Note: Only do this mod if you are running a stock/OEM map (preferably 05), and/or your map is already running rich.

    http://www.apriliaforum.com/forums/s...=1#post3372999


    Oil in airbox:
    -----------------
    Hansb was been able to move the purge valve (first link) in order to take advantage of kzmille’s airbox filter mod (second link).

    http://www.apriliaforum.com/forums/s...in-the-air-box
    http://www.apriliaforum.com/forums/showthread.php?65522-Oil-In-Air-Box&p=711194&viewfull=1#post711194


    Starter Relay:
    -------------------
    The Aprilia OEM starter relay is only rated at 50A. Because there’s around 190 peak amps (100A/120A nominal) going through the relay when the starter is running, the relay tends to burn out:

    http://www.apriliaforum.com/forums/s...me-Maintenance

    There are two common choices for replacement/upgrade: Ford and Yamaha.

    Ford Relay:
    The Ford relay is rated at 500A. It is much larger than the Aprilia relay (it still fits in the battery bay), but it definitely allows more amps to the starter motor and is less prone to burning.
    Ford: E9TZ-11450-5
    Motorcraft: SW1951C
    http://www.apriliaforum.com/forums/s...a-w-Ford-Relay

    Yamaha PnP:
    The Yahama relay is rated at 100A and plug-in-play (so this route might be easier for some people).
    Yamaha: Y-4KD-81940-00-00
    http://www.apriliaforum.com/forums/s...ay-Alternative
    http://www.boats.net/parts/detail/ya...940-00-00.html


    Starter Circuit/Ground Wires:
    ------------------------------------
    A few people have replaced the small 8 gauge wires in the starter circuit with 4 gauge wire. This increases the current that the wires can handle, which in turn allows the starter to turn faster. Some people have mentioned that this modification plus the Ford relay mod above allows their Futura to start like an inline-4 bike. Most of the people who have done this mod have also replaced the ground wire (from the left rear cylinder ground screw to the battery) which seems to help the bike run better.

    Another option pioneered by Argh Oh is adding another set of 10 gauge wires to the circuit, including the ground wire. If you don't want pull the current (get it? ) wires out and you have lengths of 10 gauge wire (or 6-8 gauge wire) sitting around, this is probably a pretty viable option for you.

    http://www.apriliaforum.com/forums/s...a-w-Ford-Relay


    Waterproof Connectors:
    ------------------------------
    A lot of the electrical issues you will see are due to corrosion in the non-waterproof connectors on the bike. Some people have just removed the problem connectors and soldered them together, but I went with a different route: waterproof connectors.

    http://www.apriliaforum.com/forums/s...oof-Connectors

    You can also get waterproof R/R connectors in the links below:
    http://www.roadstercycle.com
    http://www.easternbeaver.com/Main/El...onnectors.html


    High/Low beam switch wiring:
    ------------------------------------
    This modification allows your low beam light (center light) to stay on when your high beam lights (two outer headlights) are switched on.

    http://www.apriliaforum.com/forums/s...mod-for-Futura


    Helmet locks/hooks:
    -------------------------
    The Futura did not come standard with helmet locks (the d-ring hooks that most modern bikes have). A French user was able to create a set of steel loops that attached to the back of the seat fairing which you can then hang helmets from.

    http://mbigeard.free.fr/rst1000/acc_porte_casque.htm
    http://mbigeard.free.fr/rst1000/imag...tura%20006.jpg
    http://mbigeard.free.fr/rst1000/imag...tura%20009.jpg


    Top box using Givi MonoKey mount:
    ---------------------------------------------
    Lots of forum users have added top boxes to their Futura. emperorluigi was nice enough to add a writeup about his Givi MonoKey mount to the thread below. He has also included the CAD drawing for his custom fabricated mount.

    http://www.apriliaforum.com/forums/s...box-for-Futura
    Last edited by infrasoundxp; 04-10-2014 at 12:36 AM.

  6. #6
    apriliaforum expert RAS's Avatar
    Join Date
    Aug 2003
    Location
    PA USA
    Posts
    6,792
    The YTZ14S battery is about 1/2" shorter than OE but has more CCA capacity and Ah.

  7. #7
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117
    Quote Originally Posted by RAS View Post
    The YTZ14S battery is about 1/2" shorter than OE but has more CCA capacity and Ah.
    Added.

  8. #8
    apriliaforum expert Argh Oh's Avatar
    Join Date
    Nov 2012
    Location
    AL, USA
    Posts
    1,826
    Excellent infrasoundxp, this kind of compilation has been mentioned many times. There are a lot of mechanical things as I'm finding that have been given a lot of air time too. Mainly the King Bearing and an all time favorite, the Fuel Pressure Regulator mod. Several threads on both of these. And don't forget added/changed wiring for starter circuit.
    01 Blue #84, adopted 11/12 with: HeliBars, foam grips, 05 map, Devil cans/stock silencer, derestricted, metal QD, dash socket, R/R mod. Me: Ford relay +10g & grd, Fuel pump rewire/filter, FPR, vac hoses. CBR coils/harness+ Magnecor, clutch switch bypass. S.S. front line, RaceTech Gold valves, tapered head bearings. Lots of LED lighting mods/running lights- signals/brake LED bulbs. Flashing brake light. All lights but Hi/park/brake on dash switch. Hi beam mod, vest plug, wiring block, blue dash SMD's/Red V meter, Tune IFT. Stripped/polished rims, ESA dk tint vented screen, KB etc/axle/petal disc. FH008 soldered DC plug/added grd, soldered AC. L/R turn indicators on dash. 8/2/13 smushed. 9/22/13 back. Rehab complete 8/10/14.

  9. #9
    apriliaforum expert
    Join Date
    May 2013
    Location
    Phx, AZ
    Posts
    860
    Remove and replace the clear vaccum and sync lines with high quality lines that won't crack.

    I didn't see that though I do overlook things.
    2001 Futura 26k miles, daily driver, all black, 15t sprocket, Mille intake boot w/ K&N, SS brake lines, brown plug gone+charging wire mod, FPR mod, SS fuel QD, fork/frame sliders, bar risers, GSXR coil and harness mod
    05 Yamaha Zuma
    84 Honda Z50 THE BIKE I LEARNED TO RIDE ON!

  10. #10
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117
    Quote Originally Posted by Argh Oh View Post
    Excellent infrasoundxp, this kind of compilation has been mentioned many times. There are a lot of mechanical things as I'm finding that have been given a lot of air time too. Mainly the King Bearing and an all time favorite, the Fuel Pressure Regulator mod. Several threads on both of these. And don't forget added/changed wiring for starter circuit.
    I included the FPR mod above.

    Is there any other good threads for the king bearing other than the most recent Holy King Bearing thread?

    Do we have a good post/thread for the starter wires too? Maybe I will do one now that I have the crimp tool to do mine properly.

    Quote Originally Posted by FuTuring View Post
    Remove and replace the clear vaccum and sync lines with high quality lines that won't crack.

    I didn't see that though I do overlook things.
    I didn't add this yet. Do we have a good forum post/write-up for reference?

  11. #11
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117
    Ted from AF1 was kind enough to sticky this post.

    Added the King Bearing and Vacuum Lines to the Other Repairs post above.

  12. #12
    apriliaforum Member BadMiker's Avatar
    Join Date
    Feb 2013
    Location
    Southend on Sea - UK
    Posts
    132
    MOSFET Regulator Rectifier for those in the UK:

    http://www.electrexworld.co.uk/acatalog/RR97.html
    "A good traveler has no fixed plans and is not intent on arriving." - Lao Tzu
    2001 Futura
    Mods: HEL Front and Rear SS Brake Lines, Rear Hugger, Scott Oiler, Oxford HotGrips with eBay LED Dimmer Control, Garmin GPS and RAM Mount, Moko Frame Protection, Elextrex World MOSFeT RR with Wiring Mod, Tom Parker Metal QDs, Loud Ass Ford Transit Horn, Silicone Vacuum Lines, FPR Mod, De-Restricted Intake, 05 Map, Datatool System3 Immobiliser, Yamaha Starter Relay, BagLux Tank Cover and Alpha Bag With Power, Perelli Angel GTs, 25mm 170 Amp Power and Ground Cables, LED AUX Lights, LED Turn signals Converted to Running Lights, 3-Beam Main Beam Mod, Dash LEDs, HID Low Beam, Fuel Filler Neck Chop.
    To Come: Exhaust, Rear Shock, Forks and Brakes.

  13. #13
    apriliaforum expert Argh Oh's Avatar
    Join Date
    Nov 2012
    Location
    AL, USA
    Posts
    1,826
    infrasoundxp, you ROCK!

    There are two (?) trains of thought about the starter wiring. Replace it all w/4awg or in my case add additional 10awg to existing wiring, way easier to me. And DON'T forget the additional ground wire.
    01 Blue #84, adopted 11/12 with: HeliBars, foam grips, 05 map, Devil cans/stock silencer, derestricted, metal QD, dash socket, R/R mod. Me: Ford relay +10g & grd, Fuel pump rewire/filter, FPR, vac hoses. CBR coils/harness+ Magnecor, clutch switch bypass. S.S. front line, RaceTech Gold valves, tapered head bearings. Lots of LED lighting mods/running lights- signals/brake LED bulbs. Flashing brake light. All lights but Hi/park/brake on dash switch. Hi beam mod, vest plug, wiring block, blue dash SMD's/Red V meter, Tune IFT. Stripped/polished rims, ESA dk tint vented screen, KB etc/axle/petal disc. FH008 soldered DC plug/added grd, soldered AC. L/R turn indicators on dash. 8/2/13 smushed. 9/22/13 back. Rehab complete 8/10/14.

  14. #14
    apriliaforum expert Argh Oh's Avatar
    Join Date
    Nov 2012
    Location
    AL, USA
    Posts
    1,826
    Quote Originally Posted by RAS View Post
    The YTZ14S battery is about 1/2" shorter than OE but has more CCA capacity and Ah.
    Mine was TALLER than stock but fits. Mostly.
    01 Blue #84, adopted 11/12 with: HeliBars, foam grips, 05 map, Devil cans/stock silencer, derestricted, metal QD, dash socket, R/R mod. Me: Ford relay +10g & grd, Fuel pump rewire/filter, FPR, vac hoses. CBR coils/harness+ Magnecor, clutch switch bypass. S.S. front line, RaceTech Gold valves, tapered head bearings. Lots of LED lighting mods/running lights- signals/brake LED bulbs. Flashing brake light. All lights but Hi/park/brake on dash switch. Hi beam mod, vest plug, wiring block, blue dash SMD's/Red V meter, Tune IFT. Stripped/polished rims, ESA dk tint vented screen, KB etc/axle/petal disc. FH008 soldered DC plug/added grd, soldered AC. L/R turn indicators on dash. 8/2/13 smushed. 9/22/13 back. Rehab complete 8/10/14.

  15. #15
    apriliaforum Member
    Join Date
    Oct 2013
    Location
    United States
    Posts
    117
    Added the UK R/R link.

    Added the Starter Circuit/Ground wire mod with a link to the Ford Relay thread (lots of people in there mention the bigger/extra wires). When I do get around to adding the wires to my bike, maybe I'll post a write-up of it.

Page 1 of 2 12 LastLast

Similar Threads

  1. Futura and Caponord dash repair
    By meanstrk in forum RST1000 Futura (all years)
    Replies: 200
    Last Post: 09-25-2014, 08:18 AM
  2. Futura H pipe order information
    By Honeybadger in forum RST1000 Futura (all years)
    Replies: 37
    Last Post: 04-21-2014, 01:18 AM
  3. Futura Mirror Repair
    By ffraz in forum RST1000 Futura (all years)
    Replies: 6
    Last Post: 10-19-2010, 10:14 AM
  4. 2001 Futura spares or repair
    By jezfest in forum RST1000 Futura (all years)
    Replies: 7
    Last Post: 10-11-2010, 08:58 AM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •