Aprilia tuono conversion

Take one perfectly good Aprilia RSV1000 Mille (which you have previously spent and absolute fortune on getting to it's current state) and strip off all the front fairings.
As mine is a 1999 model the headlight is a different size to the Tuono so can't be reused but everything else is the same as the later models (Tuono's started from 2003) so all the mounting points are used again.
Most of the Tuono bodywork was sourced from Ebay, breakers yards and from one of the Aprilia forums. The top yoke is a lovely piece of art from MFW in Germany and comes complete with risers.

Here you can see the difference between the 2 top fairings. The arrows show the same top mounting point so you can see the Tuono item is both narrower and shorter. You could conceivably cut down your original but the side profile is completely different. 
You use all the existing mounting points but if you want to use the correct Tuono indicators you will need the brackets that mount to the original mirror mounts. I have mounted my indicators lower down on the fairing frame, however they are slightly less visible here.

The belly pan uses the original front 2 mounting points but requires 2 brackets for the rear. I used the original fairing brackets that were mounted to the back of the foot pegs. The right hand one is now mounted off the rear brake master cylinder mounting and the left hand is fitted behind one of the side stand bolts. The brackets need a small amount of drilling and bending to fit but do the job just fine if you don't have the Aprilia items.

Whilst the top yoke is off it's a good opportunity to re-route some of the cables. The throttle cables now run behind the ignition barrel and the wiring now runs on the inside of the fork tubes.
The MFW yoke comes with a new set of lock stops which reduce the already poor steering lock even further. However they do stop the bars (depending on which you are using) from hitting the fairing and tank on full lock. More on this later...

This is the difference in height between the original clip-on's and the new handlebars. In this picture I have used Renthal Road Bike Ultra Low.
However once the bike was completed it became apparent that the pitiful steering lock was not very practical so I have now changed to Road Bike Medium bars which have allowed me to trim some material from the lock stops adding some much needed steering lock (just slightly shy of the original amount) and still clearing the fairing. This combination of bars and riser is still slightly lower than a standard Tuono.

The brake and clutch lines are now obviously too short. Rather than order a set of Tuono lines I went for Goodridge Buildaline. In hindsight the Tuono lines would have probably been ok but I wasn't sure if all the angles would work and i wanted to switch to 2 lines for the front brake anyway.
I changed all the fittings to 90 degree and ordered a 1000mm clutch line and 750 and 675mm brake lines. These give plenty of scope for even higher bars if needed.

There is a hell of a lot of wiring to hide behind the new narrower fairing. There is some space either side of the flasher relay so a cable tied as much as I could in this area. Its a tight squeeze but the fairing goes on with a bit of a gentle push.
The Tuono fairing frame is reinforced where it mounts to the headstock (other wise the Mille version is the same) so it's an idea to keep an eye on it for signs of stress, apparently this only becomes an issue if you have lots of heavy wheelie landings...

The coil covers mount to the original frame mounts but you need to remove the fairing brackets and make up some 25mm spacers and use 50mm bolts.
The right hand coil cover was one of the few parts I couldn't track down second hand and it was quite painful having to purchase one new from Aprilia.
Rather than use the Tuono water bottle cover I chose to paint (a spare) bottle in white.

Also worth noting if you have R&G crash protectors on your Mille, they won't fit when converted to a Tuono as the holes in the coil covers dictate the mounting position so you will need to get some Tuono jobs... I didn't say this was a cheap conversion.

Pretty much finished here. Still experimenting with mirrors. The Renthal Ultra Low bars put more weight over the front which was better for the handling but the the lack of steering lock was just too compromised. The higher bars make the bike much more comfortable to ride but the front end can become quite light when cracking open the throttle.

Full Spec

1999 Aprilia RSV1000 Mille/Tuono. PVM light weight wheels. Hyper-Pro rear shock and steering damper. Arrow Titanium 60mm exhaust (ti hanger). Carbon front and rear huggers. Goodridge braided lines. R&G crash bungs. Renthal bars. DHM fold up levers. Tail tidy. LED indicators. Pro-Bold Titanium and stainless fasteners throughout.