Page 1 SERVICE STATION MANUAL 2Q000524 TUAREG 660...
Page 2 Only by requesting original aprilia spare parts can you be of purchasing products that were developed and tested during the design and development of the vehicle itself. All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability.
Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to Aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 5 INDEX OF TOPICS PRE DE DELIVERY CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK...
Page 6 INDEX OF TOPICS PRE DE DELIVERY...
Page 7 TUAREG 660 Pre-delivery Unpacking procedure of the vehicle and assembly of the accompanying components • Remove the protective cardboard box by pulling it out from above. • Position a hoist on the front of the vehicle and connect it to the handlebar using straps.
Page 8 TUAREG 660 Pre-delivery • Loosen the rear straps securing the ve- hicle to the pallet, so that the front can be raised just enough to install the front wheel. • Remove the wooden support of the forks. • Disassemble both brake callipers by removing the four M10 screws (2 per calliper).
Page 9 TUAREG 660 Pre-delivery • Tighten the two front wheel pin safety screws to a torque of 10 Nm (7.4 lbf ft). • Remove the protection present be- tween the pads inside the brake callip- ers. • Fit the two front brake callipers and tighten the four M10 screws to a torque of 50 Nm (36.9 lbf ft).
Page 10 TUAREG 660 Pre-delivery • Remove the rear straps. • Remove the vehicle from the pallet. • For greater safety, carry out the oper- ation with two people. HANDGUARD INSTALLATION PROCEDURE The following operations refer to one handg- uard but are valid for both.
Page 11 TUAREG 660 Pre-delivery REAR-VIEW MIRRORS INSTALLATION PRO- CEDURE • To install the left rear-view mirror, re- move the toothed pin protecting the threaded seat. • Insert the threaded base complete with washer on the clutch lever mount, tight- ening it to a torque of 50 Nm (36.87 lbf ft).
Page 12 TUAREG 660 Pre-delivery • Insert the rear-view mirror complete with protective rubber and lock nut on the mount. • Adjust the angle of the rear view mirror and tighten the lock nut. WINDSCREEN INSTALLATION PROCEDURE • Remove the screws together with...
Page 13 TUAREG 660 Pre-delivery - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers steering assembly - Plastic parts fixing screws Electrical system...
Page 14 TUAREG 660 Pre-delivery NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE- HICLE OR EVEN CAUSE A FIRE. - Check the battery charge by holding down the...
Page 15 TUAREG 660 Pre-delivery - Do not immerse the battery in water, or leave it exposed to moisture. - Do not connect the battery directly to wall outlets. - Do not subject the battery to short circuit by connecting cables or other metallic objects to the positive and negative terminals.
Page 16 TUAREG 660 Pre-delivery • Allow the battery to stand for at least 1 hour, before starting the charging proc- ess, without closing the six cells. This operation is extremely important in or- der to have the best battery perform- ance over time.
Page 17 TUAREG 660 Pre-delivery Functional inspection - Hydraulic braking system - Brake and clutch lever travel - Clutch - Check for correct operation - Engine - Check for correct general operation and absence of abnormal noise - Other - Documentation check:...
Page 18 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 19 TUAREG 660 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 20 TUAREG 660 Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC- TIVE IMPERMEABLE GLOVES.
Page 21 CAUTION THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY MUST BE REPLACED. • Use only aprilia ORIGINAL SPARE PARTS. • Always use the recommended lubricants and consumable material. • Lubricate the parts (when possible) before reassembling them.
Page 22 TUAREG 660 Characteristics • If there is dirt, rust, moisture, etc., carefully clean the inside of the connector using pressur- ised air. • Ensure that the cables make correct contact with the terminals inside the connectors. • Then plug in the two connectors, ensuring correct coupling (if the specific catches are present, you will hear a typical "click").
Page 23 9000 rpm up until 2000 km (1242 mi). CAUTION AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Authorised Aprilia Dealer FOR THE CHECKS INDICATED IN THE "SCHEDULED MAINTENANCE TABLE" IN THE SCHEDULED MAINTENANCE SECTION, TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Page 24 TUAREG 660 Characteristics ENGINE NUMBER The engine number is stamped on the engine crankcase, at the rear near the shock absorber. Engine No..... Dimensions and mass IMENSIONS AND MASS Specification Desc./Quantity Max. length 2220 mm (87.40 in) Max. width (at handlebar) 965 mm (37.99 in)
Page 25 LECTRONIC CONTROL SYSTEMS Specification Desc./Quantity a-PRC system (Aprilia Performance Ride Control) which includes: AEM (en- gine map management system), AEB (engine brake map man- agement system), ABS (Anti-lock braking system), ATC (traction control), AQS (Assisted shifting system without clutch assistance for both up-shifting and down-shifting) (where pro-...
Page 26 TUAREG 660 Characteristics Specification Desc./Quantity Overspeed threshold/shift light Immobilizer Fuel reserve a-PRC General warning Side stand Frame and suspensions HASSIS Specification Desc./Quantity Type Welded tubular double cradle steel frame. Steering rake angle 26.7° (measurements with respect to bare chassis) USPENSION Specification Desc./Quantity...
Page 27 TUAREG 660 Characteristics Wheels and tyres HEEL RIMS Specification Desc./Quantity Front wheel 2,15 x 21" with spokes, alloy rim channel Rear wheel 4,25 x 18" with spokes, alloy rim channel YRES Specification Desc./Quantity Front tire 90/90 - 21 M/C 54V...
Page 28 TUAREG 660 Characteristics ETRIC SCREW TIGHTENING TORQUES ON FASTENERS WITH PLASTIC COMPRESSION WITHOUT INSERTED COL- LAR OR BUSH Tightening torque: 1.5 Nm (1.10 lb ft) 2 Nm (1.47 lb ft) 3 Nm (2.21 lbf ft) CAUTION THE SCREWS WITH THREAD-LOCK SEALANT (PRE-IMPREGNATED) MUST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED.
Page 29 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 30 TUAREG 660 Special tools PECIAL TOOLS Stores code Description 021047Y Tuareg 660 engine timing wrench 021043Y Camshaft timing pin 020851Y Camshaft timing pin 9100896 Clutch bell stopper 021036Y Flywheel side crankshaft locking tool 021037Y Water pump seal insertion tool 021038Y...
Page 31 TUAREG 660 Special tools Stores code Description 020431Y Valve oil seal extractor 021039Y Pick-up distance template 021040Y Transmission shaft oil seal press-fit punch on front sprocket side 021041Y Engine fixing bracket to mount 021042Y Oil seal and clutch shaft bearing and gear...
Page 32 TUAREG 660 Special tools Stores code Description AP8140179 Valve fitting/removal support 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020713Y Flywheel puller tool 020376Y Adaptor handle 020655Y Adaptor 62x68 mm S-TOOLS - 32...
Page 33 TUAREG 660 Special tools Stores code Description 020359Y 42 x 47 mm punch 020360Y 52x55 mm punch 020414Y 28 mm punch 020712Y Handle for removing the flywheel cover AP8140190 Steering tightening tool AP8140189 Tool for mounting the oil seal for holes with diam.
Page 34 TUAREG 660 Special tools Stores code Description AP8140146 Weight 020888Y Pre-load tube clamp AP8140150 Bored shaft for bleeding plunger air 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles S-TOOLS - 34...
Page 35 INDEX OF TOPICS MAIN AINTENANCE...
Page 36 TUAREG 660 Maintenance Scheduled maintenance table NOTE THE MAINTENANCE INTERVALS PRESCRIBED BY THE SCHEDULED MAINTENANCE TABLE MUST BE CONSIDERED AS A GENERAL GUIDE FOR USING THE VEHICLE IN NORMAL RUN- NING CONDITIONS. IT MAY BE NECESSARY TO REDUCE THE MAINTENANCE INTERVALS UNDER SOME PARTIC- ULAR CONDITIONS.
Page 37 TUAREG 660 Maintenance km x 1,000 (mi x 1,000) 1 (0.6) (6.2) (12.4) (18.6) (24.9) months months Labour time (minutes) NOTE AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
Page 38 TUAREG 660 Maintenance • After removing the screws holding the coils, disconnect them from the spark plugs and remove them. • Using a special spark plug wrench, un- screw and remove them. • Check the efficiency and check the electrode gap. If they are not within the parameters, replace them.
Page 39 TUAREG 660 Maintenance • Clean the engine oil level dipstick (1) and put it back in without screwing it in • Remove it again and check the engine oil level • The level is correct if it reaches the ''MAX'' level approximately. Otherwise...
Page 40 TUAREG 660 Maintenance • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and, if necessary, replace the drainage plug sealing washers. • Remove the oil filter. • Spread a thin layer of oil on the sealing ring of the new engine oil filter.
Page 41 TUAREG 660 Maintenance Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER.
Page 42 TUAREG 660 Maintenance • Remove the air filter. Throttle body Throttle body removal To remove the throttle body, the fuel tank and the complete filter housing must first be removed. Then proceed as described: • Remove the fixing screw (1) of the air pressure sensor and disconnect the connector (2) from the sensor itself.
Page 43 TUAREG 660 Maintenance • Remove the two upper fixing screws (6) of the ECU support, freeing the ca- ble grommet that secures the tank breather pipe. • Remove the side fixing screw (7) of the ECU support. • Disconnect the fuel tank breather pipe (8) from the cable grommets on the ECU support.
Page 44 TUAREG 660 Maintenance • After removing the protective cap, dis- connect the SAS valve connector and move it sideways to access the cables connected to the filter box support. • Disconnect the two pick-up/generator sensor wiring harnesses (10) and the...
Page 45 TUAREG 660 Maintenance • Undo the four screws and remove the right frame cover. • Unscrew and remove the two fixing screws of the conduit to be able to move it far enough, to facilitate the re- moval of the throttle body.
Page 46 TUAREG 660 Maintenance • Disconnect the connector of the throt- tle body. • Disconnect the two injectors from the throttle body. • Rotate the throttle body as indicated to help removal and extract it. Throttle body installation To install the throttle body, carry out the procedures described in paragraph "Throttle body removal"...
Page 47 TUAREG 660 Maintenance Air filter housing removal To remove the filter housing, firstly remove the fuel tank and then proceed as described: • Disconnect the tank breather pipes from the filter box. • Disconnect the intake air temperature sensor connector.
Page 48 TUAREG 660 Maintenance • Disconnect and remove the two metal clamps of the manifolds. CAUTION USE NEW METALLIC CLAMPS DURING REASSEMBLY. • Unscrew and remove the three side fix- ing screws. • Partially raise the filter box, remove the metal clamp and disconnect the breather pipe.
Page 49 TUAREG 660 Maintenance Calibrated pad thickness CAUTION THE CALIBRATED PAD MUST BE ASSEMBLED KEEPING THE PRINTING OF THE THICKNESS UPWARDS. Pad thickness for adjusting valve clearance correctly: 1.75 mm (0.0689 in) 1.77 mm (0.0697 in) 1.80 mm (0.0709 in) 1.82 mm (0.0716 in) 1.85 mm (0.0728 in)
Page 50 TUAREG 660 Maintenance 2.02 mm (0.0795 in) 2.05 mm (0.0807 in) 2.07 mm (0.0815 in) 2.1 mm (0.0827 in) 2.12 mm (0.0835 in) 2.15 mm (0.0846 in) 2.17 mm (0.0854 in) 2.2 mm (0.0866 in) 2.22 mm (0.0874 in) 2.25 mm (0.0886 in) 2.27 mm (0.0894 in)
Page 51 TUAREG 660 Maintenance 2.97 mm (0.1169 in) 3 mm (0.1181 in) 3.02 mm (0.1189 in) 3.05 mm (0.1201 in) 3.07 mm (0.1209 in) 3.10 mm (0.1220 in) 3.12 mm (0.1228 in) 3.15 mm (0.1240 in) Cooling system Level check •...
Page 52 TUAREG 660 Maintenance Level check Checking brake fluid • Rest the vehicle on its stand. • For the front brake, turn the handlebar all the way to the left. • For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level as the plug.
Page 53 TUAREG 660 Maintenance BRAKE FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH THE SKIN, EYES AND PARTS OF THE MOTORCYCLE. WHEN TOPPING UP, PROTECT PARTS OF THE MOTORCYCLE IN THE VICINITY OF THE RES- ERVOIR WITH ABSORBENT MATERIAL. Recommended products DOT 4 brake fluid Synthetic brake fluid.
Page 54 TUAREG 660 Maintenance Adjusting the levers FRONT BRAKE LEVER It is possible to adjust the distance between the end of the lever (1) and the grip (2), turning the adjuster (3). • Push the control lever (1) forwards and turn the adjuster (3) until the lever (1) is at the desired distance.
Page 55 TUAREG 660 Maintenance In the event that the adjustment of the adjuster screw on the lever is not sufficient, act on the reg- ister located on the right side of the vehicle: • Loosen the nut (4) • Turn the adjuster (5) until the correct clearance is obtained.
Page 56 TUAREG 660 Maintenance To carry out vertical adjustment of the light beam: (LOW BEAM HEADLIGHTS) • Operating from the rear side of the fair- ing, under the internal bodywork, act on the adjuster ("1" left side / "2" right side). SCREWING (clockwise) the light beam is lowers;...
Page 57 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 58 TUAREG 660 Electrical system Electrical system installation Scope and applicability This document defines the position of the vehicle wiring harness, how it is routed and fixed to the chassis, instrument holder arch brace and saddle post, any problems and special checks to be made on the cable connections and routing in order to achieve vehicle reliability.
Page 59 TUAREG 660 Electrical system It is extremely important that any security-locks for the following connectors are properly connected and correctly tightened to ensure proper engine, and therefore proper vehicle, operation. Vehicle side: • Check the ECU connections. • Check Map Sensor connection.
Page 60 TUAREG 660 Electrical system THESE CONNECTORS HAVE BEEN LISTED AS THEY ARE MORE CRITICAL THAN OTHERS, AND THEIR DISCONNECTION MAY CAUSE VEHICLE BREAKDOWN OR MALFUNCTION. NAT- URALLY, IT IS ALSO NECESSARY THAT ALL OTHER CONNECTORS CONNECTED CORRECTLY TO ENSURE THAT THE VEHICLE FUNCTIONS CORRECTLY. THE INSTRUCTIONS FOR ROUT-...
Page 61 TUAREG 660 Electrical system TABLE B - OUTSIDE AIR TEMPERATURE SEN- SOR PRE-ASSEMBLY • Insert the outside air temperature sen- sor on the right side support of the instrument cluster. TABLE C - PRE-ASSEMBLY OF THE EDGE FIX- ING TIES ON THE INSTRUMENT CLUSTER SUPPORT •...
Page 62 TUAREG 660 Electrical system TABLE D - PRE-ASSEMBLY OF THE FRONT INSTRUMENT CLUSTER SUPPORT • Position the cable guide in the point in- dicated on the central instrument clus- ter support. TABLE E - HEADLIGHT PRE-ASSEMBLY • Insert the connector mount on the headlight.
Page 63 TUAREG 660 Electrical system TABLE F - IGNITION BLOCK PRE-ASSEMBLY • Secure the immobilizer wiring harness with a tie as indicated. TABLE G - RIGHT SWITCH CLUSTER PRE-AS- SEMBLY • Position the right switch cluster as in- dicated. ELE SYS - 63...
Page 64 TUAREG 660 Electrical system TABLE H - LEFT SWITCH CLUSTER PRE-AS- SEMBLY • Position the right switch cluster as in- dicated. TABLE H1 - LEFT SWITCH CLUSTER PRE-AS- SEMBLY • Always check that the wiring harness- es of the switch clusters are not...
Page 65 TUAREG 660 Electrical system TABLE I - CLUTCH SWITCH PRE-ASSEMBLY • After inserting the clutch switch in its seat routing the wiring harness as in- dicated, secure the switch using the nut so as to obtain a 4 mm protrusion of the thread, as indicated.
Page 66 TUAREG 660 Electrical system FIGURE K - FRONT ABS SENSOR • Secure the wiring harness of the front ABS sensor to the front brake line us- ing five cable guides at the points shown. FIGURE K1 - FRONT ABS SENSOR •...
Page 67 TUAREG 660 Electrical system FIGURE K2 - FRONT ABS SENSOR • Connect the ABS sensor connector and hook it to the socket positioned previously. • Using a cable clamp, secure the front ABS sensor wiring harness to the front brake line at the point indicated.
Page 68 TUAREG 660 Electrical system TABLE L1 - HANDLEBAR AND IGNITION BLOCK AREA CABLE ROUTING • Position the wiring harness of the throt- tle control and the right switch cluster to the right of the steering headstock. TABLE L2 - HANDLEBAR AND IGNITION BLOCK AREA CABLE ROUTING •...
Page 69 TUAREG 660 Electrical system TABLE L3 - HANDLEBAR AND IGNITION BLOCK AREA CABLE ROUTING • Route the immobilizer and ignition block wiring harness to the right of the steering headstock along with the pre- viously positioned harnesses. TABLE M - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA •...
Page 70 TUAREG 660 Electrical system TABLE M1 - ROUTING THE CABLES IN THE INSTRUMENT PANEL SUPPORT AREA • After passing all the cables and fixing the right instrument panel support, pull and hold the following cables: throttle control, right switch cluster, left switch cluster, clutch switch, ignition wiring and antenna wiring.
Page 71 TUAREG 660 Electrical system TABLE N - INSTRUMENT PANEL AREA CON- NECTORS CONNECTION SEQUENCE • Connect the clutch switch connector (1) positioning it in the indicated point and insert the wiring harness on the cable guide. TABLE N1 - INSTRUMENT PANEL AREA CON- NECTORS CONNECTION SEQUENCE •...
Page 72 TUAREG 660 Electrical system TABLE N2 - INSTRUMENT PANEL AREA CON- NECTORS CONNECTION SEQUENCE • Connect the left switch cluster connec- tor (3) by positioning it in the indicated connector holder. • Connect the switch cluster connector (4) and position it under the connector (3).
Page 73 TUAREG 660 Electrical system TABLE N4 - INSTRUMENT PANEL AREA CON- NECTORS CONNECTION SEQUENCE • The connectors of the following acces- sories: heated grips and anti-theft LED connector, must be positioned in the area highlighted by the circle and all passed through the indicated cable gland.
Page 74 TUAREG 660 Electrical system TABLE N6 - INSTRUMENT PANEL AREA CON- NECTORS CONNECTION SEQUENCE • Check the correct connection of all connectors, especially the ignition con- nector and the antenna connector. TABLE N7 - INSTRUMENT PANEL AREA CON- NECTORS CONNECTION SEQUENCE •...
Page 75 TUAREG 660 Electrical system Central part TABLE A - REAR BRAKE SWITCH PRE-AS- SEMBLY • Secure the rear brake switch using the special support and secure the wiring harness by means of the cable guide at the point indicated. TABLE B - SIDE-STAND SENSOR PRE-AS- SEMBLY •...
Page 76 TUAREG 660 Electrical system TABLE C - RADIATOR FAN PRE-ASSEMBLY • The small fan should have the cables facing down and the large fan facing TABLE C1 - RADIATOR FAN PRE-ASSEMBLY • Use a clamp at the point indicated to hold the wiring harness in place.
Page 77 TUAREG 660 Electrical system TABLE D - PRE-ASSEMBLY OF THE CABLE GUIDES FOR THE PASSAGE OF THE START- ER CABLES ON THE FRAME • Position the three cable guides on the frame as shown. TABLE D1 - PRE-ASSEMBLY OF THE CABLE...
Page 78 TUAREG 660 Electrical system TABLE E - PRE-ASSEMBLY OF THE CABLE GUIDE ON THE TANK • Fix the cable guide to the tank as shown. TABLE F - PRE-ASSEMBLY OF THE FUEL LEV- EL PROBE ON THE TANK • The fuel level sensor wiring harness output must face the rear of the vehicle.
Page 79 TUAREG 660 Electrical system TABLE G - ENGINE ECU BRACKET PRE-AS- SEMBLY • Pre-assemble the three edge cable guides in the indicated points on the rear part of the ECU support. TABLE H - GEAR SENSOR CABLE PASSAGE • The cable must pass adherent to the...
Page 80 TUAREG 660 Electrical system TABLE H1 - GEAR SENSOR CABLE PASSAGE • The wiring harness must pass between the rubber tube and the head of the en- gine as in the photo. TABLE H2 - GEAR SENSOR CABLE PASSAGE •...
Page 81 TUAREG 660 Electrical system TABLE I - GROUND AND ABS CABLE ON EN- GINE • Position the ground cable and the ABS connector as shown in the photo TABLE J - CONNECTION OF THROTTLE VALVE , ENGINE WATER TEMPERATURE, SECONDARY AIR VALVE •...
Page 82 TUAREG 660 Electrical system TABLE K - ENGINE HEAD AREA CONNEC- TIONS • Connect the connectors of the coils (1), of the injectors (2) and of the map sen- sor (3) making sure they are correctly inserted. TABLE K1 - ENGINE HEAD AREA CONNEC- TIONS •...
Page 83 TUAREG 660 Electrical system TABLE K2 - ENGINE HEAD AREA CONNEC- TIONS • Connect the purge valve connector. TABLE L - PROCEDURE FOR THE CORRECT FITTING OF THE ABS CONTROL UNIT CONNEC- • The initial position of the connector coupling lever must be as indicated in the figures.
Page 84 TUAREG 660 Electrical system TABLE L2 - PROCEDURE FOR THE CORRECT FITTING OF THE ABS CONTROL UNIT CON- NECTOR • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 TABLE L3 - PROCEDURE FOR THE CORRECT...
Page 85 TUAREG 660 Electrical system • The wiring harness must pass through the cable guide (3). TABLE M1 - OIL TEMPERATURE SENSOR AND OIL PRESSURE SENSOR • The wiring harness must be routed as indicated. TABLE M2 - OIL TEMPERATURE SENSOR AND OIL PRESSURE SENSOR •...
Page 86 TUAREG 660 Electrical system TABLE N - HORN CONNECTION • Connect the horn connectors as shown. TABLE O - MAIN WIRING HARNESS • The main wiring harness must be posi- tioned as indicated. ELE SYS - 86...
Page 87 TUAREG 660 Electrical system TABLE O1 - MAIN WIRING HARNESS • Check that the connector (1) of the rear brake switch is correctly hooked and objectified to the support. It must be positioned approximately 10 mm from the cable guide (2).
Page 88 TUAREG 660 Electrical system TABLE P1 - FALL SENSOR • Check that the fall sensor connector is correctly objectified on the ABS control unit support. TABLE Q - ECU • Always check the correct connection of the ECU. • Pull the grey levers that should not move in the direction of the arrow with your finger.
Page 89 TUAREG 660 Electrical system TABLE R - STARTER MOTOR AND GROUND LEAD • Check the fastening torque of the start- er motor screw (2) and that the cap is properly inserted. • Check that the ground cable screw (1) is correctly tightened and check the correct tightening torque.
Page 90 TUAREG 660 Electrical system TABLE S1 - LEFT LAMBDA PROBE • Check if the left lambda connector is correctly connected and objectified as indicated TABLE S2 - RIGHT LAMBDA PROBE • After connecting the right lambda probe, pass the wiring harness be- tween the engine and the engine mount.
Page 91 TUAREG 660 Electrical system TABLE S3 - RIGHT LAMBDA PROBE • Correctly connect the right lambda probe connector and objectify it to the appropriate support. TABLE T - LEFT ELECTRIC FAN • The wiring harness of the left electric fan (1) must pass externally to the en-...
Page 92 TUAREG 660 Electrical system TABLE T1 - RIGHT ELECTRIC FAN • The wiring harness of the right electric fan must pass internally, between the frame and the engine. • After checking the correct connection of the connector, insert it in the special housing on the left side of the frame.
Page 93 TUAREG 660 Electrical system TABLE U - VOLTAGE REGULATOR • After passing the wiring harness inside the cable guide, connect the two con- nectors to the voltage regulator TABLE V - FILTER BOX AIR TEMPERATURE SENSOR • Route the air temperature sensor wir- ing harness behind the breather pipe and inside the slot on the filter box.
Page 94 TUAREG 660 Electrical system TABLE W - MAIN WIRING HARNESS • The branch of the main wiring harness must be secured to the cross member of the frame by means of a clamp. TABLE X - FUEL LEVEL PROBE •...
Page 95 TUAREG 660 Electrical system TABLE Y - FUEL LEVEL PROBE • Check that the fuel pump connector is correctly connected. TABLE Y1 - FUEL LEVEL PROBE • Check that the fuel pump wiring har- ness is inserted in the cable guide...
Page 96 TUAREG 660 Electrical system Back side TABLE A - UNDER SEAT COMPARTMENT PRE-ASSEMBLY • Position an edge clamp (1) and two edge cable grommets (2) on the under- seat compartment. TABLE B - PRE-ASSEMBLY OF TURN INDICA- TORS ON LICENSE PLATE HOLDER •...
Page 97 TUAREG 660 Electrical system TABLE C - TAIL-LIGHT PRE-ASSEMBLY • Connect the taillight to the centre tail fairing. TABLE D - STARTER RELAY AREA CABLE PASSAGE ON LEFT SIDE OF SEAT POST • Arrange the cables on the left side and insert them in the indicated cable glands.
Page 98 TUAREG 660 Electrical system TABLE D1 - STARTER RELAY AREA CABLE PASSAGE ON LEFT SIDE OF SEAT POST • Use two zip ties at the points shown to secure all wiring harnesses. TABLE D2 - STARTER RELAY AREA CABLE PASSAGE ON LEFT SIDE OF SEAT POST •...
Page 99 TUAREG 660 Electrical system TABLE E - SIDE STAND CABLE ROUTE • The side stand sensor harness must pass as shown. TABLE E1 - SIDE STAND CABLE ROUTE • The side stand sensor harness must pass as shown. ELE SYS - 99...
Page 100 TUAREG 660 Electrical system TABLE E2 - SIDE STAND CABLE ROUTE • The side stand sensor harness must pass through the indicated cable glands. TABLE F - TAIL-LIGHTS AND TURN INDICA- TORS • Secure the branch of the main wiring harness for the rear connections using a tie at the point indicated.
Page 101 TUAREG 660 Electrical system TABLE F1 - TAIL-LIGHTS AND TURN INDICA- TORS • The taillight wiring harness must pass on the left side of the seat post and in- serted in the cable glands. • The red taping must coincide with the cable glands.
Page 102 TUAREG 660 Electrical system TABLE G - RELAY AREA CABLE ROUTING ON RIGHT SIDE • Position the relay (1) facing the inside of the motorcycle with the "RED" mark- ing on the cable. • The large tie (2) must gather 3 of the 4 branches that exit the duct.
Page 103 TUAREG 660 Electrical system TABLE G2 - RELAY AREA CABLE ROUTING ON RIGHT SIDE • Position the relay without the marking on the wiring harness, facing towards the outside of the vehicle. TABLE G3 - RELAY AREA CABLE ROUTING ON RIGHT SIDE •...
Page 104 TUAREG 660 Electrical system TABLE G4 - RELAY AREA CABLE ROUTING ON RIGHT SIDE • Position the connector with cap and rubber grommet on the tab provided on the frame. TABLE H - FUSE BOXES • Arrange the fuse boxes on the wheel arch and secure the wiring harness at the point indicated.
Page 105 TUAREG 660 Electrical system WIRING TABLE I - REAR ABS SENSOR • The wiring must be secured in the in- dicated cable gland at a distance of 300 mm from the sensor. • Secure the wiring harness using the slot in the brake calliper bleeder cap.
Page 106 TUAREG 660 Electrical system TABLE I2 - REAR ABS SENSOR • The rear ABS sensor wiring harness must pass through the cable gland (1) on the swingarm and fastened to the brake line by means of two cable glands (2).
Page 107 TUAREG 660 Electrical system TABLE I4 - REAR ABS SENSOR • Correctly connect the rear ABS sensor connector and mark it at the point indi- cated. TABLE J - OBDII CONNECTOR • The OBDII connector must be connec- ted into the special holder on the bat- tery support box.
Page 108 TUAREG 660 Electrical system General wiring diagram Key: 1. Multiple connectors 2. Horn 3. LH light switch 4. ambient air temperature sensor 5. Instrument cluster 6. RH Column light switch 7. Starter motor sensor connector 8. Rear brake switch 9. Clutch switch 10.Ignition switch...
Page 109 TUAREG 660 Electrical system 13.Right rear turn indicator 14.Right-hand fan 15.Rear turn indicator LH 16.Anti-theft system (not standard) 17.Heated handgrips (optional) 18.Anti-theft system LED 19.Front ABS sensor 20.Rear ABS sensor 21.ABS control unit 22.USB power socket (not standard) 23.Fan relay 24.Left-hand fan...
Page 110 TUAREG 660 Electrical system 51.Motorised throttle valve 52.Intake air temperature sensor 53.Engine water temperature T sensor 54.Engine speed sensor 55.Oil pressure sensor 56.GEN 11 engine control unit 57.OBD connector 58.AMP provision (not standard) 59.Front turn indicator LH 60.Front LED headlight 61.DRL...
Page 111 TUAREG 660 Electrical system • To carry out the one or more key pro- gramming procedures, up to a maxi- mum of four, you must connect the motorcycle to the diagnostic tool. • Turn key to "ON" and insert the USER CODE where required.
Page 112 TUAREG 660 Electrical system • The second key is stored and you will be asked to enter the third key (if you have one). The same operation will be repeated to store the fourth key. • To complete AND end the memorisa- tion procedure, set key to "OFF".
Page 113 TUAREG 660 Electrical system • ≤11.4 V voltage: The battery is very discharged and may also be damaged. To avoid permanent damage, the batteries without recombination maintenance should not remain completely discharged for a long time. For more details regarding the real performance of the battery, it is recommended to use the dedicated instruments that provide indications regarding the battery capacity, based on the analysis of the internal resistance.
Page 114 TUAREG 660 Electrical system If required, repeat the check, also including the connection system to the regulator's connector. Check that all measurements provide equal resist- ance values and that they are below 1 ohm. If you detect the opening of a phase or resistance values higher than the ones specified, check/re- place the stator.
Page 115 TUAREG 660 Electrical system The battery's life may be short due to abnormal energy consumption during stops. To check the residual consumption of the system, use a multimeter with miliammeter function. Prepare the multimeter with alligator clips instead of conventional tips and select the full scale of 40 mA for direct current (DC).
Page 116 TUAREG 660 Electrical system ERROR RELATED TO THE BATTERY VOLTAGE For vehicles provided with injection, it is recom- mended to check if there are any errors related to the battery voltage. The errors can be detected during the "Actual" state but, more likely, they will be in the "Memo- rised"...
Page 117 TUAREG 660 Electrical system Accelerate progressively until 5000 rpm and observe the maximum output current when the engine/ generator is cold. Decrease the speed to approximately 3000 rpm or anyway to close speeds that ensure stable rota- tion. During these checks, the generator is loaded with...
Page 118 NEVER USE A FUSE THAT IS DIFFERENT THAN WHAT IS SPECIFIED TO PREVENT DAMAGES TO THE ELECTRICAL SYSTEM OR SHORT CIRCUITS, AND THE RISK OF FIRE. CAUTION A FUSE THAT BLOWS FREQUENTLY MAY INDICATE A SHORT CIRCUIT OR OVERLOAD. CON- TACT AN authorised aprilia Dealer. To check: • To avoid an accidental short-circuit, place the power switch to "OFF".
Page 119 TUAREG 660 Electrical system • Take out one fuse at a time and check whether the filament (2) is broken. • Before replacing the fuse, find and solve, if possible, the reason that caused the problem. • If the fuse is damaged, replace it with one of the same current rating.
Page 120 TUAREG 660 Electrical system • Unhook the front part of the side panel (4) to move it out of the away and ac- cess the main fuse. • Disconnect the connector (5) to access the main fuse (O). • Remove the fuse and check whether the filament (2) is broken.
Page 121 TUAREG 660 Electrical system engine above 8000 rpm (it is not nec- essary to stay there, it is sufficient to exceed it); • Close the throttle completely and wait for the engine to go down to idle speed; • Repeat this procedure three times.
Page 122 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 123 TUAREG 660 Engine from vehicle ENG VE - 123...
Page 124 INDEX OF TOPICS NGINE...
Page 125 TUAREG 660 Engine ENG - 125...
Page 126 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 127 TUAREG 660 Power supply Fuel pump Removing To remove the fuel pump it is not necessary to re- move the fuel tank from the vehicle, but the oper- ation with the fuel tank removed is the same. Proceed as described: •...
Page 128 TUAREG 660 Power supply • Remove the fuel pump complete with seal. P SUPP - 128...
Page 129 INDEX OF TOPICS SUSP USPENSIONS...
Page 130 TUAREG 660 Suspensions Front Handlebar Removing To remove the handlebar after removing the handguards, proceed as follows: • Remove the cable guides (1). • Undo the four screws (2) and remove the U-bolt (3). • Unscrew the screw (4), move the han- dlebar to the left and remove the throt- tle control (5).
Page 131 TUAREG 660 Suspensions • Unscrew the screw (6), move the han- dlebar to the left and remove the right switch cluster (7). • Unscrew the screws (8), move the han- dlebar to the left and remove the brake master cylinder (9).
Page 132 TUAREG 660 Suspensions • After disconnecting the clutch cable from the lever, unscrew the screw (13), move the handlebar to the right and re- move the clutch lever (14). • Remove the handlebars. Front fork Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates.
Page 133 Unscrew (**) 7 clicks from fully closed (*) Stanchion protrusion (A) (***) from top yoke (excluding cover) 1 notch (*) - Clockwise (**) - Anticlockwise (***) - this type of adjustment may only be made by an Authorised Aprilia Dealer. SUSP - 133...
Page 134 TUAREG 660 Suspensions Removing the fork legs To remove the stanchions it is necessary to re- move the sump guard, lift the front wheel using a scissor lift, disconnect the front brake callipers, re- move the wheel and the mudguard. Then proceed...
Page 135 TUAREG 660 Suspensions • Extract and remove the stanchion. • During reassembly, pay attention to the adjustment of the stanchion protrusion, referring to the "Adjustment" paragraph in the "Suspensions" chapter. Draining oil NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE STANCHION BUT APPLY TO BOTH.
Page 136 TUAREG 660 Suspensions • Ensure that the cap (1) cannot rotate, and unscrew the nut (3). • With the help of a second operator while compressing the pre-load spring again, unscrew and remove the cap (1). • Extract the hydraulic braking control rod (4).
Page 137 TUAREG 660 Suspensions • Remove the spring (7). • Drain the oil into a container having sufficient capacity, extending the stan- chion several times in order to ensure the oil is drained completely. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT.
Page 138 TUAREG 660 Suspensions • Separate the sleeve from the stan- chion. • Remove the sliding bush (10), the guide bush (11), the ring (12), the oil seal (13), the snap ring (9) and the dust seal (8) from the stanchion.
Page 139 TUAREG 660 Suspensions Sleeve Check for damage and/or cracks; if it is damaged, replace it. Springs Check the condition of the springs, making sure that the length is within the acceptable limits. If not, replace the springs. MINIMUM LENGTH OF FREE SPRING: 454.2 mm (17.88 in)
Page 140 TUAREG 660 Suspensions • Insert the sleeve on the stanchion and using the special tool complete with striker fully insert the guide bush (5), the ring (4) and the oil seal (3). Specific tooling AP8140189 Tool for mounting the oil seal for holes with diam.
Page 141 TUAREG 660 Suspensions • Wait a few minutes until the oil fills all the ducts. • Pour the remaining oil. • Pump out oil a few times. • Measure the air gap between the oil level and the rim of the stanchion.
Page 142 TUAREG 660 Suspensions • After having screwed the specific tool on the damper rod, insert the spring (13) paying attention to the correct alignment. The end where the spirals are more compressed should be facing upwards. Specific tooling AP8140150 Bored shaft for bleeding plunger •...
Page 143 TUAREG 660 Suspensions • Remove the supports positioned under the stanchion allowing it to lower and tighten the cap to torque. Upper steering yoke Removal To remove the upper triple clamp it is necessary to first remove the handlebar complete with grips, throttle control, light switches, clutch lever and front brake master cylinder.
Page 144 TUAREG 660 Suspensions • Working from both sides, loosen the screws (6) securing the stanchions to the upper triple tree clamp. • Remove the two ties (7) that fasten the wiring harness of the handlebar com- ponents to the triple tree clamp.
Page 145 TUAREG 660 Suspensions • Remove the upper steering yoke (11). Installation To install the upper steering triple clamp, proceed as described: • Position the ignition assembly (1) on the upper steering triple clamp (2) and secure it by tightening the two screws (3) to torque.
Page 146 TUAREG 660 Suspensions • Place the handlebar (7) on the lower U- bolts. • Position the upper U-bolt (8) with the four fixing screws (9). • Adjust the handlebar with the "0" refer- ence mark aligned with the lower U- bolt and tighten the screws (9) to torque.
Page 147 TUAREG 660 Suspensions • Remove the rubber shim (3). • Remove the lower steering ring nut (4) using the special tool, supporting the lower clamp. Specific tooling AP8140190 Steering tightening tool • Extract the lower triple clamp (5) from below.
Page 148 TUAREG 660 Suspensions • Position the lower steering ring nut (2) and use the special tool to pre-tighten to a torque of 60 Nm (44.25 lbf ft). • Turn the handlebar to the left and right as far as it will go to seat the bearings.
Page 149 TUAREG 660 Suspensions • Insert the safety plate (5). Steering bearing Adjusting play To adjust the steering play, follow the procedure described below: • Place the vehicle so that the front wheel is off the ground. • Carry out a handlebar rotation test, using a dynamometer at the hand grip external end.
Page 150 TUAREG 660 Suspensions • Remove the rubber shim (3). • Unscrew the lower ring nut (4) using the special tool. Repeat the steering assembly tightening proce- dure in the correct manner as described: • Pre-tighten the ring nut (4) to 60 Nm (44.25 lbf ft).
Page 151 TUAREG 660 Suspensions • Unscrew and remove the counter-lock ring (2) using the appropriate tool. Specific tooling AP8140190 Steering tightening tool • Remove the rubber shim (3). • Unscrew and remove the ring nut (4) using the special tool, supporting the lower triple clamp.
Page 152 TUAREG 660 Suspensions • Remove the rubber dust ring (6). • Remove the dust seal ring (7). • Remove the bearing upper seat (8). • Remove the inner ring of the bearing (9) complete with balls. SUSP - 152...
Page 153 TUAREG 660 Suspensions • Remove the lower seat of the bearing (10) using a standard bearing extractor To remove the lower steering bearing: • After removing the inner bearing ring (11) complete with balls from the head- stock tube, heat the lower bearing seat (12) with a hot air gun to remove it and then slide off the dust cover (13).
Page 154 TUAREG 660 Suspensions • Working both on the upper and lower part of the steering headstock, insert the rotation seats of the bearings (4) up to the stop using the appropriate punch. • Lubricate the inserted seats with grease. •...
Page 155 TUAREG 660 Suspensions • Supporting the lower triple clamp, in- sert the dust seal ring (8) on the head- stock. • Supporting the lower triple clamp, in- sert the rubber dust seal (9) on the headstock. • Supporting the lower triple clamp, insert the ring nut (10) on the headstock and tighten it fully by hand.
Page 156 TUAREG 660 Suspensions • Screw the upper steering ring nut (11) and align the grooves to be able to in- sert the safety plate. • Insert the safety plate (12). Rear Shock absorbers SUSP - 156...
Page 157 IF THE SPRING PRE-LOAD IS INCREASED, IT IS NECESSARY TO INCREASE THE DAMPING OF THE SHOCK ABSORBER ACCORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING. IF NECESSARY, CONTACT AN OFFICIAL APRILIA DEALER. TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED.
Page 158 TUAREG 660 Suspensions Operating on the left side of the vehicle, it is pos- sible to access the spring pre-load adjustment knob: • Turning clockwise the pre-load increa- ses, vice versa by turning anti-clock- wise it decreases. Operating on the right side of the vehicle, in cor-...
Page 159 TUAREG 660 Suspensions Removing To remove the shock absorber it is necessary to first remove the fuel tank and unload the weight from the shock absorber itself. Then proceed as described: • Unscrew the locking nut of the lower screw and remove it.
Page 160 TUAREG 660 Suspensions • Insert the upper screw from the left side of the vehicle and the nut, tightening it to torque. • Insert the lower screw from the left side of the vehicle and the nut, tightening it to torque.
Page 161 TUAREG 660 Suspensions • Working on the right hand side of the vehicle, unscrew the nut fastening the single linkage to the frame, pulling the screw out from the left hand side to re- move it. • Remove the single linkage.
Page 162 TUAREG 660 Suspensions ALWAYS REPLACE THE OIL SEALS WITH NEW COMPONENTS AFTER DISASSEMBLING THE COMPONENTS OF THE SINGLE LINKAGE Installing To install the linkages, after securing the front of the vehicle with straps, use a scissor lift to support the centre of the vehicle and keep the rear shock absorber unloaded.
Page 163 TUAREG 660 Suspensions • Insert the fixing screw of the single link- age to the dual linkage from the left side and the lock nut from the opposite side, tightening it to the prescribed tor- que. SUSP - 163...
Page 164 INDEX OF TOPICS CHAS HASSIS...
Page 165 TUAREG 660 Chassis Wheels Front wheel Removal To proceed with the removal of the front wheel, lift the motorcycle using an appropriate centre stand, remove the brake callipers and proceed as descri- bed: • Loosen the two screws (1) on the clamp of the left stanchion.
Page 166 TUAREG 660 Chassis • Remove the complete wheel (3). • Remove the spacer (4) on the right side of the wheel. REMOVAL OF INTERNAL WHEEL COMPO- NENTS To proceed with the removal of the internal wheel components, proceed as described: •...
Page 167 TUAREG 660 Chassis • Using a generic puller, proceed with the extraction of the bearing as descri- bed: • Insert the first part of the tool (A) on the bearing and screw the pin (B). • Insert the second part (C) and the nut (D).
Page 168 TUAREG 660 Chassis REMOVAL OF EXTERNAL WHEEL COMPO- NENTS To proceed with the removal of the external wheel components, proceed as described: • Remove the six fixing screws (9) of the tone wheel / front disc. • Remove the tone wheel (10) (if present).
Page 169 TUAREG 660 Chassis • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings do not fall within the control parameters: • Replace both wheel bearings. ALWAYS REPLACE BOTH BEARINGS.
Page 170 TUAREG 660 Chassis Installing For the assembly and installation of the front wheel, follow the sequence indicated and proceed as described: INSTALLATION OF EXTERNAL COMPONENTS • Position the brake disc (1) on the hub making sure of the correct alignment, determined by the markings which must face outwards, as indicated.
Page 171 TUAREG 660 Chassis INSTALLATION OF INTERNAL COMPONENTS • Working on the right side of the rim, using the appropriate punch, insert the bearing (3) as far as it will go. Specific tooling 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor •...
Page 172 TUAREG 660 Chassis • Insert the internal spacer (7) in the di- rection indicated on the left side of the rim. • Having positioned the bearing (8) in its seat, insert it as far as it will go using the appropriate punch.
Page 173 TUAREG 660 Chassis • Position the wheel (11) and insert the pin (12). • Tighten the pin (12) to the prescribed torque. • Tighten the two screws (13) on the clamp of the right stanchion to the pre- scribed torque.
Page 174 TUAREG 660 Chassis Rimozione To proceed with the removal of the rear wheel, lift the motorcycle using an appropriate rear stand, and proceed as described: • Working from both sides, loosen the locking nut (1) of the adjuster (2) and then screw the adjuster to eliminate tension on the chain tensioner.
Page 175 TUAREG 660 Chassis • Adequately protect the swingarm and remove the chain (7) from the rear sprocket and remove the rear wheel (8). REMOVAL OF EXTERNAL WHEEL COMPO- NENTS To proceed with the removal of the external wheel components, proceed as described: •...
Page 176 TUAREG 660 Chassis • Unscrew the five screws (12) and re- move the flange (13). • Remove the spacer (14). • Unscrew the three screws (15) and re- move the tone ring (16). • Undo the five screws (17) and remove the brake disc (18).
Page 177 TUAREG 660 Chassis REMOVAL OF INTERNAL WHEEL COMPO- NENTS To proceed with the removal of the internal wheel components, proceed as described: • Working on the right side of the wheel, remove the oil seal (19). • Using special pliers, remove the circlip (20).
Page 178 TUAREG 660 Chassis • Remove the bearing (21). NOTE REPEAT THE OPERATION DESCRIBED ABOVE, TO REMOVE THE BEARING ON THE OPPOSITE SIDE OF THE WHEEL. • Remove the internal spacer (22). REAR SPROCKET SUPPORT DISASSEMBLY • Having removed the sprocket support from the wheel, remove the external spacer (23).
Page 179 TUAREG 660 Chassis Remove the five spring washers (25). • Remove the chain guard (26). • Remove the sprocket (27). • Remove the oil seal (28). CHAS - 179...
Page 180 TUAREG 660 Chassis • Remove the seeger ring (29). • Following the procedure described above for bearing removal, and re- move the bearing (30) present in the sprocket support. Checking CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR.
Page 181 TUAREG 660 Chassis • Check the condition of the seals; replace if damaged or excessively worn. ALWAYS REPLACE BOTH SEALS TOGETHER. ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE. REAR WHEEL AXLE • Use a dial gauge to check the wheel axle eccentricity (1).
Page 182 TUAREG 660 Chassis • Using the appropriate punch, insert the bearing as far as it will go. Specific tooling 020376Y Adaptor handle 020655Y Adaptor 62x68 mm • Insert the circlip (3). • Position the oil seal (4) flush with the outside of the rear sprocket support.
Page 183 TUAREG 660 Chassis • Position the chain guard (6) on the sprocket support. • Position the five spring washers (7) on the sprocket support. • Torque tighten the five chain/rear sprocket guard fixing nuts in the order A-B-C-D-E. • Insert the external spacer (9).
Page 184 TUAREG 660 Chassis INSTALLATION OF INTERNAL WHEEL COM- PONENTS To proceed with the installation of the internal wheel components, initially proceed from the right side as described: • Position the bearing (10) in its seat and use the appropriate punch to insert as far as it will go.
Page 185 TUAREG 660 Chassis • Fit the internal spacer (14) from the op- posite side. • Position the bearing (15) in its seat and use the appropriate punch to insert as far as it will go. Specific tooling 020376Y Adaptor handle...
Page 186 TUAREG 660 Chassis • Position the tone ring (17) on the hub and torque tighten the three fixing screws. • Working from the left side, position the flange (18) on the hub, insert the five screws and tighten them to the speci- fied torque in the following order A-B- C-D-E.
Page 187 TUAREG 660 Chassis • Position the sprocket support (21) on the flange. • Position the wheel (22) in its seat in- serting the chain (23) on the sprocket. • Working from the right side of the mo- torcycle, lift the wheel and insert the pin (24) complete with the chain tensioner (25).
Page 188 TUAREG 660 Chassis • Insert the washer (27), the nut (28) and tighten it by hand. • Working from both sides, use the ad- justment register screw (29) to bring the chain to the correct tension and tighten the locking nuts (30).
Page 189 TUAREG 660 Chassis • Tighten the rear wheel locking nut to the prescribed torque. • Rotate the wheel a few times to check that it does not stick. Swinging arm Removing Using straps, block the front part, position a scissor lift centrally to keep the rear part raised when re- moving the swingarm.
Page 190 TUAREG 660 Chassis • Unscrew then fixing nut (4) from the swingarm pin and the relative washer (5). • Operating from the right side of the ve- hicle and supporting the swingarm, ex- tract the swingarm pin (6). • Remove the swingarm (7) taking care to recover the flat washers on both sides (8).
Page 191 TUAREG 660 Chassis • Remove the 4 gaskets (11). • Using a suitable punch, remove the roller bearings. Specific tooling 020376Y Adaptor handle 020441Y 26 x 28 mm adaptor • To remove the chain guide, refer to the specific procedure in the "chain guide sliders" para- graph, in the "frame and suspension"...
Page 192 TUAREG 660 Chassis PERNO FORCELLONE Con un comparatore controllare che l'eccentricita' del perno non superi il valore limite. In caso con- trario sostituire il perno. Eccentricita' massima del perno: 0,2 mm (0.0078 in). Installing To proceed with the installation of the swingarm, proceed as described: •...
Page 193 TUAREG 660 Chassis • Position the 4 gaskets (4) on the swing- arm to the level of the internal machin- ing as shown in the image. • Working from both sides, insert the "T" bush (5) complete with shoulder wash- er (6).
Page 194 TUAREG 660 Chassis • Insert the washer (10) and the nut (11) on the pin, tightening it to torque. • Position the "T" bush (12) on the swing- arm if previously removed. • Connect the dual linkage to the swing-...
Page 195 TUAREG 660 Chassis Removing In order to remove the front sprocket, having slack- ened the tension of the final drive chain, proceed as follows: • Unscrew the four fixing screws (1) of the left frame protection (2) and re- move it.
Page 196 TUAREG 660 Chassis • Remove the chain guide (9). • Remove the fastener screw (10) of the sprocket complete with the "T" bush (11) and the cup spring washer (12). • Remove the front sprocket (13) from the transmission shaft and free it from the drive chain.
Page 197 TUAREG 660 Chassis Inspection To check the state of wear of the front sprocket, simply check that the teeth of the sprocket are not worn or damaged. In this case, replace the rear sprocket and the final drive chain also.
Page 198 TUAREG 660 Chassis • Having positioned the new pre-impreg- nated M10x25 screw (4) used to fasten the pinion, along with the "T" bush (5) and the spring washer (6), tighten it to the prescribed torque. • Position the breather pipe (7) in the sprocket cover (8) as indicated.
Page 199 TUAREG 660 Chassis • Position the frame cover (13) and after having positioned the four screws (14) tighten them to torque. • Restore the drive chain to the correct tension, following the specific procedure described in the "Adjustment" paragraph. Drive chain Removing The transmission chain, although "closed", has a...
Page 200 TUAREG 660 Chassis • Remove the outer plate (4). • Remove the outer O-ring rings (5). • Remove the inner plate (6). • Collect the inner O-ring rings (7) and completely remove the transmission chain. CHAS - 200...
Page 201 TUAREG 660 Chassis inspection To check the wear of the drive chain, use the chain checking instrument, P/N: Ognibene - 529510001. The different chain pitches which may be checked with the instrument are indicated on the instrument itself. There are three reference markings for each chain pitch indicated on the instrument.
Page 202 TUAREG 660 Chassis • Place the outer O-rings (3) on the pins. • Compress the outer plate (4) using the appropriate generic tool. CAUTION BE CAREFUL NOT TO COMPRESS TOO THE OUTER PLATE TOO MUCH AS THIS COULD SEIZE THE CHAIN.
Page 203 TUAREG 660 Chassis Adjusting To check the clearance: • Shut off the engine. • Rest the vehicle on the side stand. • Select neutral. • Check that the vertical deflection of the bottom section of the chain, measured at a distance of 320 mm (12.59 in) from...
Page 204 TUAREG 660 Chassis • Use the adjuster screw (3) to adjust the chain clearance checking that the ref- erences (4) match on both sides of the vehicle. • Using a gauge make sure that the dis- tance is the same on both sides.
Page 205 TUAREG 660 Chassis CHAIN GUIDE In order to remove the chain guide, the swingarm must be removed beforehand. Then proceed as described: • Remove the three fixing screws chain guide, along with the cups. • Remove the chain guide. CHAIN ROLLER •...
Page 206 TUAREG 660 Chassis Rimozione LEFT RIDER FOOTREST To disassemble and remove the left rider footrest it is necessary to first remove the frame protection and the side stand. Then proceed as described: • Unscrew the fixing screw (1) of the shift lever (2) taking care to retain the two rubber o-rings (3) and the washer (4).
Page 207 TUAREG 660 Chassis • Separate the rubber part from the foot rest. THE RUBBER PART CAN ALSO BE REMOVED WITHOUT REMOVING THE FOOT REST FROM THE SUPPORT PLATE. • Loosen the fixing nut (11) of the swing- arm pin. •...
Page 208 TUAREG 660 Chassis RH RIDER FOOTREST To disassemble and remove the right rider footrest it is necessary to first remove the frame protection. Then proceed as described: • Unscrew the two fixing screws (1) of the rear brake master cylinder (2).
Page 209 TUAREG 660 Chassis • After removing the pin (8) extract the foot rest (9) complete with spring (10). CAUTION ALWAYS USE A NEW SLIT PIN DURING REASSEMBLY . • Separate the rubber part from the foot rest. THE RUBBER PART CAN ALSO BE REMOVED WITHOUT REMOVING THE FOOT REST FROM THE SUPPORT PLATE.
Page 210 TUAREG 660 Chassis • Using a pin with adequate dimensions (length greater than 350 mm and di- ameter less than/equal to 30 mm), push the swingarm pin from left to right out of its seat so that the pin used re- places the swingarm pin.
Page 211 TUAREG 660 Chassis • While pressing the side plates, remove the complete pedal. • Check that the plates (4) are aligned correctly before dismantling the pedal, taking care not to lose the ball (5) and the spring (6). • Unscrew and remove the two screws (7) to separate the rubber part from the footrest.
Page 212 TUAREG 660 Chassis • To remove the footrest support, re- move the two screws (9). • Remove the footrest support (10). Installazione LEFT RIDER FOOTREST To assemble and install the left rider footrest, pro- ceed as follows: • Position the chain roller (1) and tighten the screw (2) to the prescribed torque.
Page 213 TUAREG 660 Chassis • Position the spacer (6) between the plate and the frame, insert the screw (7) screwing it manually. • Tighten part the nut (5) to the prescri- bed torque. • Tighten the screw (7) to the prescribed torque.
Page 214 TUAREG 660 Chassis • Insert the spring (8) on the footrest (9) checking the correct orientation and in- sert the pin (10). • Position the washer (11) on the pin and insert a new split pin (12) locking it by bending the ends as shown.
Page 215 TUAREG 660 Chassis RH RIDER FOOTREST To assemble and install the right rider footrest, proceed as follows: • Position the rear brake switch on the support plate and tighten the two screws (1). • Insert the swingarm pin (2) into the...
Page 216 TUAREG 660 Chassis • Reassemble the exhaust and after in- serting the screw (8), tighten the nut (9) to torque. • Assemble the rubber part on the foot- rest paying attention to insert it correct- ly in point "A" and then point "B".
Page 217 TUAREG 660 Chassis • Insert the brake lever fixing pin (15) complete with the two rubber o-rings (16) and washer (17). • Tighten the pin to the prescribed tor- que. • Connect the brake lever return spring (18). • Reposition the rear brake master cyl- inder in its seat and tighten the two fixing screws (19) to torque.
Page 218 TUAREG 660 Chassis • Insert the retainer plate (3) in the rub- ber part. • Join the rubber part with the footrest by tightening the two screws (4) to torque. • Assemble the footrest opening/closing components, checking the correct ori- entation of the plates (5) before insert- ing the spring (6) and the ball (7).
Page 219 TUAREG 660 Chassis • Position the washer (9) on the pin and insert a new split pin (10) locking it by bending the ends as shown. Stand Side stand REMOVAL To remove the side stand, proceed as described: • Disconnect and remove the two return springs (1) from the stand.
Page 220 TUAREG 660 Chassis • Remove the special screw (6) used to fasten the centre stand and then sep- arate it from the plate. • Remove the washer (7). NOTES FOR THE REFIT PHASE: • Check the correct positioning of the side stand sensor, in particular that the sensor pin is engaged in the hole on the stand.
Page 221 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 222 TUAREG 660 Braking system Foreword The ABS system consists of the following elements: 1. ABS Modulator. 2. Front brake callipers. 3. Rear brake calliper. 4. Front brake master cylinder. 5. Rear brake master cylinder. The ABS system is a device that prevents wheel locking in case of an emergency braking, thus in- creasing vehicle stability when braking, compared with a conventional braking system.
Page 223 - the ABS system is working. If the ABS disabled indication remains: NOTE SHOULD THIS OCCUR, CONTACT AN Aprilia Approved Dealer. NOTE IN CASE OF EXTENDED REAR WHEEL ROTATION WITH THE FRONT ONE LOCKED (BURNOUT, MOTORCYCLE ON THE CENTRE STAND, ETC.) THE SYSTEM CAN BE DEACTIVATED AUTO- MATICALLY WHEN THE ABS and a-PRC INDICATOR LIGHT STAYS ON.
Page 224 SUCH BEHAVIOUR IS TO BE CONSIDERED NORMAL AND DOES NOT CREATE MALFUNC- TIONS IN THE SYSTEM. IF THE GAP FOR ONE OR BOTH SENSORS IS NOT WITHIN THE TOLERANCE INDICATED BE- LOW, TAKE THE MOTORCYCLE TO AN Approved Aprilia Dealer Characteristic Distance between tone wheel and front sensor 0.5 - 2.00 mm (0.020 - 0.079 in)
Page 225 TUAREG 660 Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Rear system circuit 3. Front brake callipers 4. Rear brake calliper BRAK SYS - 225...
Page 226 TUAREG 660 Braking system 5. Front brake master cylinder 6. Rear brake pump 7. Front brake control lever 8. Rear brake pedal 9. Front brake circuit inlet solenoid valve (normally open) 10.Rear brake circuit inlet solenoid valve (normally open) 11.Front brake circuit outlet solenoid valve (normally closed) 12.Rear brake circuit outlet solenoid valve (normally closed)
Page 227 TUAREG 660 Braking system At this stage the rider cannot increase the pressure on the callipers (3-4) and the system reduces the pressure on the callipers partially. Excess fluid temporarily fills the "reservoir" located inside the ABS modulator until the ABS pump (14) automatically activates to direct the fluid to the brake master (5 -6).
Page 228 TUAREG 660 Braking system Modulator ABS MODULATOR REPLACEMENT To replace the ABS modulator it is necessary to remove the fuel tank, the side protections of the frame, the ECU and its support. Then proceed as described: • Disconnect the purge valve (1) from the frame.
Page 229 TUAREG 660 Braking system • Disconnect the connector (4) of the fall sensor from the cable guide. Unscrew the fixing screw and move the sensor (5) aside to aid the removal procedure of the ABS modulator. • Unscrew and remove the four fixing...
Page 230 TUAREG 660 Braking system • Remove the ABS modulator with sup- port and disconnect the connector. • Remove the two screws (11) and sep- arate the support (12) from the ABS modulator (13). Pay attention to recov- er the two bushes (14).
Page 231 TUAREG 660 Braking system In case of replacement of the ABS control unit, ensure that the new one has caps on all four hydraulic connections and then proceed as follows: • After connecting the new ABS control unit hydraulically and electrically, it must be activated/ recognised.
Page 232 TUAREG 660 Braking system • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 • If the initial position of the connector and of the driving lever is not as shown in the "A1"...
Page 233 TUAREG 660 Braking system • Disconnect the ABS sensor wiring from the two cable glands. • Suitably protect the swingarm to pre- vent it from coming into contact with the brake fluid when removing the rear brake calliper. • Unscrew and remove the special screw complete with washers fixing the brake hose to the calliper.
Page 234 TUAREG 660 Braking system • Using a punch, extract the locking pin of the pads. • Remove the brake pads. • Separate the brake calliper from the support. • Remove the rubber grommet from the calliper. BRAK SYS - 234...
Page 235 TUAREG 660 Braking system • Remove the rubber grommet from the support. • Remove the metal plate from the brake calliper. • Remove the metal plate from the sup- port. NOTE DURING REASSEMBLY, LUBRICATE THE RUBBER GROMMETS ENOUGH TO INSERT THEM IN THEIR SEATS AND THE SLIDING PINS.
Page 236 TUAREG 660 Braking system • Position the metal plate on the brake calliper, checking for correct orienta- tion. • Lubricate the rubber grommet as nec- essary and insert it on the support. NOTE CHECK THE CONDITION BEFORE POSITIONING THE RUBBER GROMMET. IF DETERIORATED OR HAS CRACKS, REPLACE IT WITH A NEW ONE.
Page 237 TUAREG 660 Braking system • Position the brake pads in the calliper and check they have been fitted cor- rectly. • Insert the brake pads retaining pin. • Insert the split pin in the retaining pin of the brake pads.
Page 238 TUAREG 660 Braking system • Suitably protect the swingarm to pre- vent it from coming into contact with the brake fluid when connecting the brake line. • Insert the special screw complete with new washers fixing the brake line and tighten it to the prescribed torque.
Page 239 TUAREG 660 Braking system Removal NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH. To remove the front brake calliper, after having adequately protected the rim to prevent it from coming into contact with the brake fluid when re- moving the front brake calliper, it is necessary to drain the front brake system.
Page 240 TUAREG 660 Braking system To separate the brake calliper from the support, follow the procedure described below: • Remove the cotter pin from the pin • Using a punch, extract the locking pin of the pads. • Remove the brake pads.
Page 241 TUAREG 660 Braking system • Remove the rubber grommet from the calliper. • Remove the rubber grommet from the support. • Remove the metal plate from the brake calliper. • Remove the metal plate from the sup- port. NOTE DURING REASSEMBLY, LUBRICATE THE RUBBER GROMMETS ENOUGH TO INSERT THEM IN THEIR SEATS AND THE SLIDING PINS.
Page 242 TUAREG 660 Braking system Installing To install the front brake calliper it must be assem- bled before positioning it in place. • Position the metal plate on the support, checking for correct orientation. • Position the metal plate on the brake calliper, checking for correct orienta- tion.
Page 243 TUAREG 660 Braking system • Lubricate the two pins sufficiently and connect the brake calliper to the sup- port. • Position the brake pads in the calliper and check they have been fitted cor- rectly. • Insert the brake pads retaining pin.
Page 244 TUAREG 660 Braking system • Position the front brake calliper com- plete with support on the fork stanchion and fasten it by tightening the two fixing screws to the prescribed torque. • Suitably protect the rim to prevent it from coming into contact with the brake fluid when connecting the brake line.
Page 245 TUAREG 660 Braking system Removal To remove the rear brake disc, after removing the wheel, simply remove the five screws. Disc Inspection The operations must be carried out with the brake disc fitted on the wheel. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points.
Page 246 TUAREG 660 Braking system Installing After checking the integrity and the state of wear of the brake disc, if it is not replaced with a new disc, proceed as described to carry out the fitting: • Position the brake disc on the rim, mak- ing sure it is in the correct direction of installation.
Page 247 TUAREG 660 Braking system • Remove the tone wheel (2) (if applica- ble). • Remove the brake disc (3). Disc Inspection • The following operations must be car- ried out with the brake discs fitted on the wheel; they refer to a single disc, but are valid for both.
Page 248 TUAREG 660 Braking system Installing After checking the integrity and the state of wear of the brake discs, if they are not replaced with new discs, proceed as described to carry out the fitting: THE FOLLOWING OPERATIONS REFER TO A SINGLE DISC BUT APPLY TO BOTH.
Page 249 TUAREG 660 Braking system To remove the front brake pads proceed as de- scribed: • Remove the cotter pin (1) from the pin. • Remove the pin (2). • Remove the two brake pads (3). DO NOT OPERATE THE BRAKE LEVER ONCE THE BRAKE...
Page 250 TUAREG 660 Braking system • Insert the brake pads (1) in the calliper and check they have been fitted cor- rectly. • Insert the locking pin (2). • Insert split pin (3) in the pin. • Check the correct operation of the brake system.
Page 251 TUAREG 660 Braking system • Remove the pin (2). • Remove the pads (3). DO NOT OPERATE THE BRAKE LEVER ONCE THE BRAKE PADS HAVE BEEN REMOVED, AS THIS MAY FORCE THE PISTONS OUT FROM THEIR SEATS AND ALLOW BRAKE FLUID TO ESCAPE.
Page 252 TUAREG 660 Braking system • Insert split pin (3) in the pin. • Check the correct operation of the brake system. Bleeding the braking system PREPARATION OF THE VEHICLE • It is important to ensure that there is always a sufficient quantity of brake fluid in the tank.
Page 253 TUAREG 660 Braking system • Remove the rubber protection cover of the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con- tainer to collect the fluid.
Page 254 TUAREG 660 Braking system • The pump starts running. • While the pump is performing a rotation cycle, operate and release the front brake lever until the message diagnostic tool cycle completion is received. • This procedure allows the air to circulate and accumulate.
Page 255 TUAREG 660 Braking system • Repeat the operation until the are no air bubbles in the fluid going into the container. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
Page 256 TUAREG 660 Braking system Removal To remove the front brake master cylinder it is necessary to previously drain the front system, re- move the rear view mirror and handguard com- plete with support. Then proceed as described: • Remove the rubber grommets that fas- ten the brake line to the wiring harness.
Page 257 TUAREG 660 Braking system Rimozione To remove the rear brake pump it is necessary to previously empty the oil from the system. Then proceed as described: • Unscrew the four screws (1) and re- move the frame cover (2) to access the fixing screw of the rear brake fluid res- ervoir.
Page 258 TUAREG 660 Braking system • Rotate the pin (8) to release the brake pump control rod and slide it out in or- der to remove it. • Unscrew the two fastening screws (9) of the rear brake master cylinder and remove it.
Page 259 TUAREG 660 Braking system • Unscrew the fixing screw (3) complete with washer (4) of the rear brake sys- tem cable guides, taking care to recov- er the spacer (5). THE MODULATOR-REAR BRAKE CALLIPER BRAKE LINE (6) IS POSITIONED EXTERNAL- •...
Page 260 TUAREG 660 Braking system • Unscrew the fixing screw (3) complete with washer (4) of the rear brake sys- tem cable guides, taking care to recov- er the spacer (5). THE MODULATOR-REAR BRAKE MASTER CYLINDER BRAKE LINE (6) IS POSITIONED IN- TERNALLY.
Page 261 TUAREG 660 Braking system • Unscrew the two screws (5) and re- move the retainer plates (6) of the front brake lines. • Remove the two rubber grommets (7) that fasten the brake line to the wiring harness. • Unscrew the fixing screw (8) complete with the two washers (9) and remove the brake line (10).
Page 262 TUAREG 660 Braking system • Unscrew the three screws (3) and re- move the support plate (4) of the en- gine to the frame to facilitate the removal of the cable clamp under- neath. • Unscrew the two screws (5) and re- move the retainer plates (6) of the front brake lines.
Page 263 TUAREG 660 Braking system • Working on both front brake callipers, remove the screws (9) complete with washers (10). • Remove the connecting pipe of the two callipers (11). • Cut the clamp (12) and remove the brake line (13).
Page 264 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 265 TUAREG 660 Cooling system Removal To proceed with the removal of the water pump, proceed as described: • Remove the five fixing screws (1) of the water pump cover. • Remove the water pump cover (2) complete with gasket (3).
Page 266 TUAREG 660 Cooling system • Using a rubber hammer, remove the gear of the water pump (7) complete with washer (8). • From the outside of the cover, using a punch remove the sealing ring (9). • Remove the oil seal (10).
Page 267 TUAREG 660 Cooling system • Using the special punch, fully seat the oil seal on the cover. Specific tooling 020376Y Adaptor handle 020414Y 28 mm punch • Apply a light coat of grease to the slid- ing surface of the oil pump gear (2).
Page 268 TUAREG 660 Cooling system • Screw the first component of the seal ring installation tool (A) onto the gear of the water pump. Specific tooling 021037Y Water pump seal insertion tool • Insert the gear complete with tool on the cover.
Page 269 TUAREG 660 Cooling system • Ensure that the pin (A) cannot rotate, and then tighten the nut until the seal- ing ring is fully seated. • Insert the impeller (5) and tighten it to the prescribed torque. Removing the radiator To remove the radiator it is necessary to remove the fuel tank, sump guard and the side fairings.
Page 270 TUAREG 660 Cooling system • Remove the metal clamps (3). • Remove the metal clamps (4) and dis- connect the radiator hoses. USE NEW METALLIC CLAMPS (4) DURING RE- ASSEMBLY. • Remove the two fastening screws (5) of the radiator to the support.
Page 271 TUAREG 660 Cooling system • Remove the clamp (7), disconnect the connector (8) of the right electric fan. • Remove the clamp (9), disconnect the connector of the left electric fan. • Remove the radiator, sliding it out from the left side of the vehicle.
Page 272 TUAREG 660 Cooling system • Turn the handlebar all the way to the left and remove the three fixing screws (3) of the expansion tank. • Remove the expansion tank (4). • To refit the expansion tank, carry out the procedure described previously for removal in reverse order.
Page 273 TUAREG 660 Cooling system • Move the valve cover aside without dis- connecting it from the hose and re- move it. Installing To install the thermostatic valve, proceed as de- scribed: • After checking the integrity and effec- tive operation, insert the thermostatic valve in its seat, taking care of its cor- rect positioning.
Page 274 INDEX OF TOPICS BODYW ODYWORK...
Page 275 TUAREG 660 Bodywork Seat To remove the saddle, proceed as described: • Insert the key in the lock of the saddle located on the left side fairing. Turn the key clockwise. • Slightly press the middle of the sad- dle's rear part so that the hook is easily released;...
Page 276 TUAREG 660 Bodywork • Keeping the screw (6) still, unscrew the nut (7). • Remove the support (8) for the handg- uard, taking care to recover the "T" bush (9). LEFT HAND GUARD • Remove the front fixing screw (1).
Page 277 TUAREG 660 Bodywork • Unscrew the lock nut (6) and recover the washer (7). • Remove the handguards support (8). • Retrieve the inner spacer (9). • To assemble the handguards, carry out the procedure described above in reverse order.
Page 278 TUAREG 660 Bodywork • Working on the left hand side of the motorcycle, remove the five screws (1). • Remove the two screws (2) that fasten the right instrument panel support to the chassis. • Remove the two rubber cable clamps.
Page 279 TUAREG 660 Bodywork • Unscrew the fixing screw (5) of the throttle control and slide it off the han- dlebar to remove it. • Disconnect the right switch cluster con- nector (6) from the guide on the instru- ment panel support and disconnect it.
Page 280 TUAREG 660 Bodywork • Remove the two screws (2) that fasten the right instrument panel support to the chassis. • Remove the two rubber cable clamps (3). • Remove the clamps (4) to release the wiring. • Using compressed air, remove the left hand grip (5).
Page 281 TUAREG 660 Bodywork • Disconnect the first connector of the left switch cluster (6) from the guide on the instrument panel support and dis- connect it • Disconnect the second connector of the left switch cluster (7). • Unscrew the fixing screw (8) of the right switch cluster and slide it off the han- dlebar to remove it.
Page 282 TUAREG 660 Bodywork Instrument panel To remove the instrument panel the top fairing must be removed beforehand. Then proceed as described: • Unscrew the four fixing screws (1) of the instrument panel visor (2) and re- move it • Unscrew the three screws (3) complete with washers (4) securing the instru- ment panel.
Page 283 TUAREG 660 Bodywork • Release the connector (2) from the guide and disconnect it to remove the light cluster. • Remove the nine screws (3) in order to separate the light cluster (4) from the headlight bezel (5). • The two parts of the headlight bezel can be separated by unhooking them from each other.
Page 284 TUAREG 660 Bodywork Turn indicators To remove the turn indicators, proceed as descri- bed: FRONT TURN INDICATORS - REMOVAL THE OPERATIONS DESCRIBED BELOW RE- FER TO A SINGLE TURN INDICATOR, BUT ARE VALID FOR BOTH • Undo the fixing screw and remove the turn indicator.
Page 285 TUAREG 660 Bodywork • Disconnect the turn indicator connec- tor. • Ensure that the screw cannot rotate and unscrew the internal nut and re- move the indicator. Disassembling the lock To remove the saddle lock, after removing the saddle, proceed as described: •...
Page 286 TUAREG 660 Bodywork • Remove the lock control lever (5) and the spring (6). • Remove the fork spring (7). • Remove the cable support plate (8). • Working from the external side of the left tail fairing, remove the lock block (9).
Page 287 TUAREG 660 Bodywork Taillight assy. To remove the rear light cluster, after removing the saddle, proceed as described: • Unscrew the four screws (1) that fasten the licence plate holder. • Disconnect the connector (2) of the rear light cluster and the connectors (3) of the turn indicators to remove the li- cense plate holder.
Page 288 TUAREG 660 Bodywork • Remove the three upper fixing screws (6) of the tail fairing. • Remove the tail fairing complete with the rear light cluster. • Remove the four screws (7) in order to separate the tail fairing (8) from the rear light cluster (9).
Page 289 TUAREG 660 Bodywork Side body panels To disassemble the side panels it is necessary to first remove the side tail fairings. Then proceed as described: The operations described refer to a side panel but are valid for both • Remove the two screws with relative washers and separate the side panel from the side tail fairing.
Page 290 TUAREG 660 Bodywork • Remove the lower screw (4) that se- cures the side fairing to the radiator. • Disconnect the side fairing from the pin (5) on the tank and at the same time disconnect the pin (6) on the side fair- ing from the engine mount.
Page 291 TUAREG 660 Bodywork License plate holder To remove the license plate holder, follow the pro- cedure described below: • Unscrew the four screws (1) that fasten the licence plate holder. • Disconnect the connector (2) of the rear light cluster and the connectors (3) of the turn indicators to remove the li- cense plate holder.
Page 292 TUAREG 660 Bodywork Sump guard To remove the sump guard, follow the procedure described below: • Remove the two front screws (1) • Supporting the sump guard, remove the two rear screws (2). • Remove the sump guard (3). •...
Page 293 TUAREG 660 Bodywork • Keeping the spacer pads still, unscrew the locking nuts (5) and recover the washers. Fuel tank To remove and disassemble the fuel tank, it is necessary to remove the saddle, the battery and the side fairings. Then proceed as described: •...
Page 294 TUAREG 660 Bodywork • Remove the two front screws (4). • Remove the tank cover (5). • Working on both sides, remove the two fastening clips (6) of the air ducts. • Disconnect the pin (7) of the air duct from the tank.
Page 295 TUAREG 660 Bodywork • Working from both sides, unscrew the screws (9) and remove the central crosspiece (10). • Remove the four screws (11), discon- nect the OBDII connector (12) and re- move the battery box (13). • Disconnect the electric connector (14) of the fuel pump and release the wiring harness from the cable guide (15).
Page 296 TUAREG 660 Bodywork • Unscrew the screw (18) to remove the cable guide (19) and free the fuel pipe. • Extract the hose clamp (20) and dis- connect the breather pipe (21). • Remove the metallic clamp (22) and disconnect the fuel vapour recovery pipe (23).
Page 297 TUAREG 660 Bodywork • Remove the two clamps indicated and disconnect the connector of the fuel level sensor. • Remove the fuel tank. In order to remove the fuel level sensor: • After unscrewing the four fixing screws, extract the fuel level sensor (25).
Page 298 TUAREG 660 Bodywork To remove the flange: • After unscrewing the four screws (26) remove the flange (27). • Remove the gasket (28). To remove the fuel pump, proceed as described: • Unscrew and remove the ring nut (29) of the fuel pump.
Page 299 TUAREG 660 Bodywork Rear wheelhouse To remove the rear wheel arch, it is necessary to first remove the saddle, battery, the battery box, the fuel tank, the body parts that make up the side tail fairings, including the side panels and the li- cense plate holder.
Page 300 TUAREG 660 Bodywork • Remove the central screws (5). • Extract the rear wheel arch (6) far enough to be able to disconnect the wiring harness (8) from the cable guides (7). Front mudguard To remove the front mudguard, follow the proce- dure described below: •...
Page 301 TUAREG 660 Bodywork • Remove the mudguard from the front as indicated. • To remove the reflectors, unscrew the nut on the inside of the mudguard. • Remove the reflector. DURING INSTALLATION PAY ATTENTION TO THE PIN ON THE REFLECTOR THAT MUST BE INSERTED IN THE CORRESPONDING HOLE ON THE MUDGUARD.
Page 302 TUAREG 660 Bodywork • Remove the instrument panel cover. Windscreen To remove the windscreen, follow the procedure described below: • Remove the four fixing screws paying attention to collect the bushes posi- tioned on the support. • Remove the complete windscreen.
Page 303 TUAREG 660 Bodywork • Remove the four rubber grommets. DURING REASSEMBLY, MAKE SURE THE BUSHES ARE CORRECTLY POSITIONED IN PLACE. Instrument cluster support To remove the instrument panel support, it is nec- essary to first remove the front fairing complete with the light unit, the side fairings, air ducts and the instrument panel.
Page 304 TUAREG 660 Bodywork • Remove the clamps (3) to release the wiring. • Disconnect the connector of the right turn indicator (4) and the connector (5) of the ambient temperature sensor to remove the right instrument panel sup- port. •...
Page 305 TUAREG 660 Bodywork • Unscrew the two fixing screws (9) of the left instrument panel support, tak- ing care to recover the "T" bushes. • Remove the left instrument panel support. • To reassemble the instrument panel support, carry out the procedures described above in reverse order, consulting the "electrical system"...
Page 306 TUAREG 660 Bodywork Radiator cover To remove the radiator cover it is necessary to firstly remove the side and lower fairings. Unhook the hooks on the radiator cover and re- move it. Battery To remove the battery, proceed as described: •...
Page 307 TUAREG 660 Bodywork • Grip the battery (7) firmly and remove it from its seat, lifting it. • Put the battery away on a level surface, in a cool and dry place. • Refit the rider saddle. CHECK THAT THE CABLE TERMINALS AND BATTERY LEADS ARE: - IN GOOD CONDITION (NOT CORRODED OR COVERED BY DEPOSITS);...
Page 308 TUAREG 660 Bodywork To remove the central part, proceed as described: • Remove the screw (4) located under the tail fairing. • On both sides of the vehicle, remove the side fixing screws (5) of the tail fair- ing. •...
Page 309 TUAREG 660 Bodywork • Remove the four screws (7) in order to separate the tail fairing (8) from the rear light cluster (9). Side air deflectors To remove the air ducts, it is first necessary to re- move the fuel tank cover. Then proceed as descri- bed: •...
Page 310 ABS: 222 Air filter: 41, 46–48 Battery: 112, 306 Brake: 244, 246, 248, 250, 255, 256, 258 Brake disc: 244, 246 Brake pads: 248, 250 Brake pump: 255, 256 Chain: 25, 191, 199, 204 Drive chain: 25, 199 Electrical system: 13, 25, 58 Engine oil: 38 Fairings: 289 Fork: 132, 134, 137, 139...
Page 311 Mirrors: 281 Mudguard: 300 Oil filter: 41 Radiator: 269, 306 Rear wheel: 173 Recommended products: 37 Scheduled maintenance: 36 Shock absorbers: 156 Side fairings: 289 Side stand: 219 Spark plug: 37 Stand: 219 Tank: 271, 293 Throttle body: 42, 46 Transmission: 24 Turn indicators: 284 Tyres: 27...

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