APRILIA Tuono 660 2021 Service Station Manual
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APRILIA Tuono 660 2021 Service Station Manual

Workshop manual
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Table of Contents

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SERVICE STATION MANUAL
2Q000453
RS 660 - Tuono 660

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Summary of Contents for APRILIA Tuono 660 2021

  • Page 1 SERVICE STATION MANUAL 2Q000453 RS 660 - Tuono 660...

  • Page 2: The Value Of Service

    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

    INDEX OF TOPICS PRE DE DELIVERY CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM 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: Electrical System

    RS 660 - Tuono 660 Pre-delivery Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - 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...

  • Page 8: Charge Level

    RS 660 - Tuono 660 Pre-delivery WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL. CAUTION 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.
  • Page 9 RS 660 - Tuono 660 Pre-delivery - Do not knock, throw or subject the battery to violent shocks. - Do not carry the battery together with flammable, explosive or sharp objects. - NEVER attempt to open the battery. - Keep the connecting poles clean and firmly secured at all times. - Do not immerse the battery in water, or leave it exposed to moisture.
  • Page 10 RS 660 - Tuono 660 Pre-delivery • Check that air bubbles come out of the cells; let the liquid flow into the cells for at least 20 minutes. • If no air bubbles escape and the liquid does not flow, tap lightly on the bottom of the container until the liquid begins to flow into the cells.

  • Page 11: Static Test

    RS 660 - Tuono 660 Pre-delivery - Abnormal noise Static test Static control after the test drive: - Restarting when warmed up - Idling - Uniform turning of the steering - Possible leaks - Radiator electric fans operation Functional inspection - Hydraulic braking system - Brake and clutch lever travel - Clutch - Check for correct operation...
  • Page 12 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 13: Safety Rules

    RS 660 - Tuono 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 14: Maintenance Rules

    RS 660 - Tuono 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 15: Reassembling The Components

    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 16 Preferably do not exceed 7500 rpm during the first 1000 km (621 mi) and 9500 rpm from 1000 to 2000 km (1243 mi). AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "RECOMMENDED PRODUCTS" TABLE IN THE SCHEDULED MAIN-...
  • Page 17 RS 660 - Tuono 660 Characteristics TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE. Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.

  • Page 18: Dimensions And Mass

    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), AWC (wheelie control), AQS (assisted shift CHAR - 18...
  • Page 19 RS 660 - Tuono 660 Characteristics Specification Desc./Quantity system for clutchless upshifts and downshifts), PIT (pit lane speed limiter) (where applicable). Capacities APACITY Specification Desc./Quantity Fuel tank capacity (including reserve) 15 l (3.30 UK gal; 3.96 US gal) Fuel tank reserve capacity 3.5 l (0.77 UK gal;...

  • Page 20: Tightening Torques

    RS 660 - Tuono 660 Characteristics Frame and suspensions RAME Specification Desc./Quantity Type Adjustable composite structure aluminium frame with cast el- ements. Steering rake angle 24.1° (measurements with respect to bare chassis) USPENSIONS Specification Desc./Quantity Front fork Adjustable upside-down hydraulic fork with 41 mm (1.61 in) stanchions Front stroke 120 mm (4.72 in)
  • Page 21 RS 660 - Tuono 660 Characteristics ENERAL TIGHTENING TORQUES FOR SELF TAPPING SCREWS FOR PLASTIC 2.9 mm 3.9 mm 4.2 mm 5 mm Tightening torque 2 Nm (1.48 lb ft) 2 Nm (1.48 lb ft) 3 Nm (2.21 lb ft) 3 Nm (2.21 lb ft) CAUTION THE SCREWS WITH THREAD-LOCK SEALANT (PRE-IMPREGNATED) MUST BE REPLACED...
  • Page 22 RS 660 - Tuono 660 Characteristics RONT WHEEL Pos. Description Type Quantity Torque Notes Wheel axle 65 Nm (47.94 lb ft) Front brake disc flanged hex fixing M8x20 25 Nm (18.43 lb ft) screw RONT FORK Pos. Description Type Quantity Torque Notes 22.5 Nm (16.60 lbf ft)
  • Page 23 RS 660 - Tuono 660 Characteristics Pos. Description Type Quantity Torque Notes Cap locknut 15 Nm (11.06 lbf ft) Plunger fastening screw 22.5 Nm (16.60 lbf ft) Wheel pin safety locking screw 18 Nm (13.27 lbf ft) ABS sensor screw 6 Nm (4.42 lb ft) RONT BRAKE CALLIPER Pos.
  • Page 24 RS 660 - Tuono 660 Characteristics TEERING Pos. Description Type Quantity Torque Notes SHC screw fastening upper plate to M8x40 25 Nm (18.43 lb ft) stanchion SHC screw fastening lower plate to M8x35 25 Nm (18.43 lb ft) stanchion Upper yoke fixing cap 100 Nm (73.75 lb ft) Headstock tightening counter-lock Manual tightening...
  • Page 25 RS 660 - Tuono 660 Characteristics LUTCH CONTROL Pos. Description Type Quantity Torque Notes Clutch control fastener screw 10 Nm (7.37 lb ft) RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Screw fastening front brake master 10 Nm (7.37 lb ft) cylinder CHAR - 25...
  • Page 26 RS 660 - Tuono 660 Characteristics NSTRUMENTS Pos. Description Type Quantity Torque Notes TCCIC screw fastening instrument M6x20 6.5 Nm (4.79 lb ft) cluster support to chassis Central part CHAR - 26...
  • Page 27 RS 660 - Tuono 660 Characteristics RAME Pos. Description Type Quantity Torque Notes SHC screws fastening the saddle M10x30 50 Nm (36.87 lb ft) mounting frame Self-locking nut for locking the fas- 50 Nm (36.87 lb ft) tening pin of the saddle mounting frame Hex screw fixing engine bracket to M8x20...
  • Page 28 RS 660 - Tuono 660 Characteristics RONT MUDGUARD NGINE FAIRING Pos. Description Type Quantity Torque Notes Front mudguard fixing screw 3 Nm (2.21 lbf ft) Pos. Description Type Quantity Torque Notes Tank breather couplings 3 Nm (2.21 lbf ft) Flanged screw fastening fuel pump M5x15 4 Nm (2.95 lb ft) CHAR - 28...
  • Page 29 RS 660 - Tuono 660 Characteristics OCKS Pos. Description Type Quantity Torque Notes Screws fastening cap and tray 4 Nm (2.95 lb ft) Ignition switch assembly fixing shear M8x40 Bring to break head screw SHC screw fastening ignition switch M8x40 20 Nm (14.75 lbf ft) assembly CHAR - 29...
  • Page 30 RS 660 - Tuono 660 Characteristics ILTER BOX Pos. Description Type Quantity Torque Notes SWP self-tapping screws fixing tem- 0.5-0.8 Nm (0.36-0.59 perature sensor lb ft) TCB flanged screws fastening filter M5x20 1-1.2 Nm (0.73-0.88 lb box lid SWP TCB flanged screw fastening M5x20 1-1.2 Nm (0.73-0.88 lb bleed valve bracket...
  • Page 31 RS 660 - Tuono 660 Characteristics OOLING SYSTEM Pos. Description Type Quantity Torque Notes Screw fixing radiator to support 6 Nm (4.42 lb ft) Screw fixing the electric fan to the ra- 7.5 Nm (5.53 lb ft) diator ILENCER Pos. Description Type Quantity...
  • Page 32 RS 660 - Tuono 660 Characteristics Pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening 13 Nm (9.58 lbf ft) nuts OOTRESTS Pos. Description Type Quantity Torque Notes TE flanged screws fixing footpegs to 45 Nm (33.19 lb ft) the crankcase SHC screws fixing passenger foot- M8x45...
  • Page 33 RS 660 - Tuono 660 Characteristics INKAGE Pos. Description Type Quantity Torque Notes Gearbox lever pin fixing nut 25 Nm (18.43 lb ft) Spherical pin fixing tie rod to gear 8.5 Nm (6.26 lbf ft) Loct. 243 lever EAR BRAKE PUMP Pos.
  • Page 34 RS 660 - Tuono 660 Characteristics TAND Pos. Description Type Quantity Torque Notes Pin fixing side stand to support 12 Nm (8.85 lbf ft) Loct. 243 Nut fixing stand pin to bracket 30 Nm (22.12 lb ft) Loct. 243 Screws fixing the stand to the engine 45 Nm (33.19 lb ft) crankcase CHAR - 34...
  • Page 35 RS 660 - Tuono 660 Characteristics RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Button head, hex. socket voltage M6x30 6 Nm (4.42 lb ft) regulator fixing screws Flanged hex screw for horn fixing 15 Nm (11.06 lbf ft) Starter relay cables fastening screws 4 Nm (2.95 lb ft) Screw fastening ground cable to the...

  • Page 36: Back Side

    RS 660 - Tuono 660 Characteristics Back side EAR BODYWORK Pos. Description Type Quantity Torque Notes Handle fixing screws 18 Nm (13.27 lbf ft) CHAR - 36...
  • Page 37 RS 660 - Tuono 660 Characteristics EAR WHEEL Pos. Description Type Quantity Torque Notes Sprocket fixing nuts 50 Nm (36.87 lb ft) TE flanged screws fastening rear M8x20 25 Nm (18.43 lb ft) brake disc Rear wheel axle nut 120 Nm (88.50 lbf ft) WINGARM Pos.
  • Page 38 RS 660 - Tuono 660 Characteristics HOCK ABSORBER Pos. Description Type Quantity Torque Notes Flanged, self-locking shock absorber 50 Nm (36.87 lb ft) fastening nuts EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes TE flanged screws fastening rear 25 Nm (18.43 lb ft) With thread-lockers brake calliper CHAR - 38...
  • Page 39 RS 660 - Tuono 660 Characteristics Pos. Description Type Quantity Torque Notes Rear ABS sensor fastening TBEI M5x16 6 Nm (4.42 lb ft) With thread-lockers screw Engine RANKCASE Pos. Description Type Quantity Torque Notes Crankcase halves mating screws M10x65 1) 15 Nm (11,06 lbf ft) - Lubricate with oil 2) 20 Nm+30°...
  • Page 40 RS 660 - Tuono 660 Characteristics EAD COVER Pos. Description Type Quantity Torque Notes Spark plugs 12 Nm (8.85 lbf ft) Head cover fastening screws 10 Nm (7.38 lbf ft) TE flanged coil fixing screw M6x16 12 Nm (8.85 lbf ft) ALVES Pos.
  • Page 41 RS 660 - Tuono 660 Characteristics Pos. Description Type Quantity Torque Notes Water temperature sensor 20 Nm (14.75 lbf ft) Thermostat cover flanged hex fixing 6 Nm (4.43 lbf ft) screw Secondary air cover fixing screws M5x16 6 Nm (4.43 lbf ft) Stud bolts 10 Nm (7.38 lbf ft) Flanged nut fixing cylinder head...
  • Page 42 RS 660 - Tuono 660 Characteristics RANKSHAFT Pos. Description Type Quantity Torque Notes Connecting rod screws 1) 15 Nm (11,06 lbf ft) - Lubricate with Pankl 2) 20 Nm+110° (14,75 lbf ft+110°) CHAR - 42...
  • Page 43 RS 660 - Tuono 660 Characteristics OMPLETE GEAR ELECTOR ESMODROMIC Pos. Description Type Quantity Torque Notes Retention plate fixing hex socket 12 Nm (8.85 lbf ft) Pre-impregnated screws Gear selector drum fixing flanged 25 Nm (18.44 lbf ft) hex screw Gear sensor fixing round headed 6 Nm (4.43 lbf ft) screws...
  • Page 44 RS 660 - Tuono 660 Characteristics UBRICATION Pos. Description Type Quantity Torque Notes Oil filter 15 Nm (11.06 lbf ft) Oil filter joint 28.5 Nm (21.02 lbf ft) Oil pressure sensor 13 Nm (9.59 lbf ft) Crankcase cap 20 Nm (14.75 lbf ft) Oil pressure regulation valve 42 Nm (30.98 lbf ft) Drainage plug...
  • Page 45 RS 660 - Tuono 660 Characteristics ATER PUMP Pos. Description Type Quantity Torque Notes Water pump cover fixing screws 12 Nm (8.85 lbf ft) Water pump impeller 4.5 Nm (3.32 lbf ft) LUTCH Pos. Description Type Quantity Torque Notes Clutch fastening nut 175 Nm (129.07 lbf ft) Screws for springs 10 Nm (7.37 lb ft)
  • Page 46 RS 660 - Tuono 660 Characteristics LUTCH COVER Pos. Description Type Quantity Torque Notes Clutch control lever flanged hex fix- M6x20 10 Nm (7.38 lbf ft) ing screw Clutch cover flanged hex fixing screw 12 Nm (8.85 lbf ft) CHAR - 46...
  • Page 47 RS 660 - Tuono 660 Characteristics LYWHEEL COVER Pos. Description Type Quantity Torque Notes Flywheel cover flanged hex fixing 12 Nm (8.85 lbf ft) screw Flywheel cover cap 20 Nm (14.75 lbf ft) LYWHEEL GNITION Pos. Description Type Quantity Torque Notes Starter motor fastening screws M6x35...

  • Page 48: Index Of Topics

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 49 RS 660 - Tuono 660 Special tools PECIAL TOOLS Stores code Description 021044Y Intake camshaft disarming lever 021043Y Camshaft timing pin (2 pieces) 020851Y Camshaft timing pin 669N/5 (BETA) Ratchet torque wrench, rectangular at- tachment 736/10.10-1 (STAHLWILLE) Insert holder for torque wrench with rec- tangular attachment 9100896 Clutch bell stopper...
  • Page 50 RS 660 - Tuono 660 Special tools Stores code Description 021036Y Flywheel side crankshaft locking tool 021037Y Water pump seal insertion tool 021038Y Crankshaft support U-bolt 020431Y Valve oil seal extractor 021039Y Pick-up distance template 021040Y Transmission shaft oil seal press-fit punch on front sprocket side S-TOOLS - 50...
  • Page 51 RS 660 - Tuono 660 Special tools Stores code Description 021041Y Engine fixing bracket to mount 021042Y Oil seal and clutch shaft bearing and gear shaft punch 020980Y Piston assembly ring AP8140179 Valve fitting/removal support 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020713Y...
  • Page 52 RS 660 - Tuono 660 Special tools Stores code Description 020376Y Adaptor handle 020414Y 28 mm punch 020712Y Handle for removing the flywheel cover AP8140190 Steering tightening tool AP8140145 Oil seal assembly tool AP8140146 Weight AP8140149 Guard for assembly operations S-TOOLS - 52...
  • Page 53 RS 660 - Tuono 660 Special tools Stores code Description 020888S Pre-load tube clamp 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles S-TOOLS - 53...

  • Page 54: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 55: Scheduled Maintenance Table

    RS 660 - Tuono 660 Maintenance Scheduled maintenance table NOTE HALVE THE SERVICE INTERVALS INDICATED IF THE VEHICLE IS USED IN PARTICULARLY RAINY OR DUSTY CONDITIONS, ON POOR ROADS OR FOR HIGH PERFORMANCE RIDING. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.

  • Page 56: Recommended Products

    RS 660 - Tuono 660 Maintenance (1) Check and clean and adjust or replace, if necessary, before every journey. (2) Check and clean, adjust or replace if necessary every 621 mi (1,000 km). (3) Replace at whichever of the following occurs first: 25.000 mi (40,000 Km) or 4 years. SCHEDULED MAINTENANCE TABLE _ USA mi x 1.000 (km x 1.000) 0.6 (1)

  • Page 57: Spark Plug

    RS 660 - Tuono 660 Maintenance Product Description Specifications Lithium-based grease Lithium-calcium soap based grease colour - black, contains EP (Extreme Pressure) additives, excellent water-re- pellent properties Anti-freeze liquid, ready to use, colour red Ethylene glycol antifreeze liquid with or- ASTM D 3306 - ASTM D 4656 - ASTM D ganic inhibition additives.

  • Page 58: Engine Oil

    RS 660 - Tuono 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 59 RS 660 - Tuono 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.
  • Page 60 RS 660 - Tuono 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 61: Engine Oil Filter

    RS 660 - Tuono 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 62: Throttle Body Removal

    RS 660 - Tuono 660 Maintenance • Remove the filter box cover. • Remove the filter retainer.. • Remove the filter. Throttle body Throttle body removal To remove the throttle body, the fuel tank and the complete filter box must first be removed. Then proceed as described: •...
  • Page 63 RS 660 - Tuono 660 Maintenance • Disconnect the two vacuum pipes (3) from the air pressure sensor (4). • Disconnect the injector connectors (5). • Release the metal clamps (6) which hold the throttle body to the manifolds. • After having removed the throttle body from the manifolds and unhooked the safety hook of the connector (7), dis-...

  • Page 64: Air Filter Housing

    RS 660 - Tuono 660 Maintenance • Disconnect the fuel hose from the fit- ting (8). Air filter housing Air filter housing removal To remove the filter housing, firstly remove the fuel tank and then proceed as described: • Disconnect the intake air temperature sensor connector (1).
  • Page 65 RS 660 - Tuono 660 Maintenance • Remove the filter box cover (3). • Remove the filter retainer (4). • Remove the filter (5). • If it needs cleaning, remove the blow- by filter (6). MAIN - 65...
  • Page 66 RS 660 - Tuono 660 Maintenance • Remove the two screws (7) securing the filter box to the cable support of the main wiring harness. • Remove the two fixing screws (8) of the ECU support to the filter housing. •...
  • Page 67 RS 660 - Tuono 660 Maintenance • Remove the central screw (14) inside the filter box which is fixed on the can- ister support below. • Remove the 4 screws (15) securing the intake duct. • Remove the 2 intake ducts (16). •...

  • Page 68: Checking The Ignition Timing

    RS 660 - Tuono 660 Maintenance • Disconnect the vacuum valve (18) from the support. • Remove the complete filter box (19). • If necessary, it is possible to separate the upper duct from the filter box base. Checking the ignition timing To proceed with the engine timing check, it is nec- essary to first remove the fuel tank, the side fair- ings, the complete filter box, the throttle body, the...
  • Page 69 RS 660 - Tuono 660 Maintenance Specific tooling 020851Y Camshaft timing pin • Insert the second pin (2) through the holes in the timing gear of the exhaust camshaft. • Insert the third pin (3) through the holes in the timing gear of the intake cam- shaft.
  • Page 70 RS 660 - Tuono 660 Maintenance • Unscrew and remove the special screw (7) complete with metal washer (8). • Using a magnet, extract the chain ten- sioner (9). • Undo and remove the two screws (10) and the plate (11) complete with slider. •...
  • Page 71 RS 660 - Tuono 660 Maintenance • Remove the timing gear (4) from the intake camshaft by sliding it off the chain. • Position the specific tool (5) on the ex- ternal cam of the intake shaft as shown and rotate the intake camshaft forward to free the valves.
  • Page 72 RS 660 - Tuono 660 Maintenance • Remove the cam tower (7) complete with screws. • Depending on which valve needs ad- justment, remove the intake camshaft (8) or the exhaust camshaft. • Remove the bucket tappet (9) of the valve requiring adjustment.

  • Page 73: Components Installation

    RS 660 - Tuono 660 Maintenance CAUTION THE CALIBRATED PAD MUST BE ASSEMBLED KEEPING THE PRINTING OF THE THICKNESS UPWARDS. COMPONENTS INSTALLATION • After lubricating the bucket tappets, the rotation seats of the camshafts and the shafts them- selves, position them on the head. The exhaust camshaft has two grooves in the indicated point.
  • Page 74 RS 660 - Tuono 660 Maintenance • Tighten the ten fixing screws (6) of the cam tower to the prescribed torque fol- lowing the indicated sequence. • Insert the second centring pin (2) on the exhaust camshaft at the point shown.
  • Page 75 RS 660 - Tuono 660 Maintenance • Using a punch, simulate the tension of the transmission chain and check that the holes of the fixing screws of the timing gears are centred with respect to the slotted holes of the gears them- selves.
  • Page 76 RS 660 - Tuono 660 Maintenance • Insert the chain tensioner (9) complete with a new O-Ring. • Insert the special screw (7) complete with a new metal washer (8) and tight- en it to the prescribed torque. • Disarm the chain tensioner by using a punch through the hole in the fitting.

  • Page 77: Checking The Valve Clearance

    RS 660 - Tuono 660 Maintenance • Using the special tools and a T40 torx insert, having inserted the missing screw, tighten the two fixing screws (4) of the intake camshaft timing gear to the prescribed torque. Specific tooling 669N/5 (BETA) Ratchet torque wrench, rectan- gular attachment 736/10.10-1 (STAHLWILLE) Insert holder for torque wrench with rectangular attachment...
  • Page 78 RS 660 - Tuono 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) 1.87 mm (0.0736 in)
  • Page 79 RS 660 - Tuono 660 Maintenance 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) 2.3 mm (0.0905 in) 2.32 mm (0.0913 in)

  • Page 80: Cooling System

    RS 660 - Tuono 660 Maintenance 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 • Shut off the engine and wait until it cools off.

  • Page 81: Braking System

    RS 660 - Tuono 660 Maintenance • Remove the cap (3) and top up the system. Braking system Level check Checking brake fluid • Rest the vehicle on its stand. • For the front brake, turn the handlebar all the way to the left. •...
  • Page 82 RS 660 - Tuono 660 Maintenance CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESER- VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING-UP PROCEDURE. TO AVOID SPILLING FLUID WHILE TOPPING UP, KEEP THE LEVEL OF THE FLUID IN THE RES- ERVOIR PARALLEL WITH THE EDGE OF THE RESERVOIR ITSELF (IN HORIZONTAL POSITION).

  • Page 83: Front Brake Lever

    RS 660 - Tuono 660 Maintenance Rear braking system In order to top up the rear braking system, the rear side fairing panel must be removed. • Unscrew the fastener screw (5) of the rear brake reservoir while restraining the nut to prevent it from turning. •...

  • Page 84: Rear Brake Lever

    CAUTION TO ADJUST THE PLAY OF THE GEAR LEVER, PLEASE CONTACT AN Official Aprilia Dealer. IF YOU ARE ADE- QUATELY TRAINED AND EXPERIENCED, REFER TO THE INSTRUCTIONS IN THE WORKSHOP BOOKLET AVAILA- BLE ALSO AT ANY Official Aprilia Dealer.

  • Page 85: Headlight Adjustment

    RS 660 - Tuono 660 Maintenance In the event that the adjustment of the adjuster on the lever is not sufficient, act on the register loca- ted on the right side of the vehicle: • Loosen the nut (4) • Turn the adjuster (5) until the play is between 1 and 3 mm (0.039 and 0.12 in).

  • Page 86: Removing System Components

    RS 660 - Tuono 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).
  • Page 87 RS 660 - Tuono 660 Maintenance To disassemble the components of the evapora- tive system, first remove the fuel tank, the com- plete filter box and then proceed as described: • Disconnect the connectors (1) of the coils from the canister support. •...
  • Page 88 RS 660 - Tuono 660 Maintenance • Using pliers for metal clamps, remove the two clamps (7) and disconnect the pipes (8). • Cut the two clamps (9) to be able to separate the canister from the support. • If the vacuum valve (10) needs to be replaced, after removing the metal clamps (11) and disconnecting the pipes (12), disconnect the connector...

  • Page 89: Index Of Topics

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...

  • Page 90: Electrical System Installation

    RS 660 - Tuono 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 91 RS 660 - Tuono 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: • License plate led light connector. •...

  • Page 92: Front Side

    RS 660 - Tuono 660 Electrical system • Check coils 1 and 2 connection. • Check Purge Valve connection. • Check Map Sensor connection. CAUTION 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.
  • Page 93 RS 660 - Tuono 660 Electrical system TABLE B - FRONT ABS SENSOR • Fix the front ABS sensor (1) to the right fork end, pass the wiring (2) inside and lock it with a clamp (3) in the indicated point.
  • Page 94 RS 660 - Tuono 660 Electrical system TABLE B2 - FRONT ABS SENSOR • Fasten the wiring of the front ABS sen- sor to the brake pipe using 3 other cable clamps (5). • Place the connector inside the instru- ment support.
  • Page 95 RS 660 - Tuono 660 Electrical system TABLE E - INSTRUMENT CLUSTER SUPPORT ZONE • The grouped wiring must be blocked with a clamp (1) on the support located inside the instrument cluster support and with an additional clamp (2) in the indicated point.
  • Page 96 RS 660 - Tuono 660 Electrical system Central part TABLE A - REAR STOP SENSOR PRE-ASSEM- • Lock the rear stop sensor (1) to the pedal support and pass the wiring through the cable grommet (2) as shown. TABLE B - PRE-ASSEMBLY OF VOLTAGE REGULATOR ON THE LEFT INNER SIDE •...
  • Page 97 RS 660 - Tuono 660 Electrical system TABLE C - HORN PRE-ASSEMBLY • Fix the horn (1) using the special brack- et to the support as indicated and po- sition the cable grommet clip (2). TABLE D - ELECTRIC FAN PRE-ASSEMBLY •...
  • Page 98 RS 660 - Tuono 660 Electrical system TABLE E2 - MAIN WIRING HARNESS • Pass the main wiring as shown. TABLE E3 - MAIN WIRING HARNESS • Pass the main wiring as shown. ELE SYS - 98...
  • Page 99 RS 660 - Tuono 660 Electrical system FIGURE F - FLYWHEEL • The alternator wiring (1) must pass be- hind the support (2) of the brake pipes and through the cable grommet (3). TABLE F1 - FLYWHEEL • Pass the wiring (4) of the voltage reg- ulator behind the radiator pipe.
  • Page 100 RS 660 - Tuono 660 Electrical system TABLE G1 - HORN AND STAND SENSOR • The wiring of the stand sensor (3) must pass behind the radiator pipes, fas- tened to the cable grommet (4) on the radiator support bracket and the two cable grommets (5) located inside the lower left fairing.
  • Page 101 RS 660 - Tuono 660 Electrical system TABLE J - PROCEDURE FOR THE CORRECT FITTING OF THE ABS CONTROL UNIT CON- NECTOR • Pass the ABS modulator wiring as in- dicated. Components present: 1) ABS modulator wiring 2) ABS modulator connector TABLE J1 - PROCEDURE FOR THE CORRECT FITTING OF THE ABS CONTROL UNIT CONNEC- •...
  • Page 102 RS 660 - Tuono 660 Electrical system TABLE J4 - PROCEDURE FOR THE CORRECT FITTING OF THE ABS CONTROL UNIT CON- NECTOR • If the initial position of the lever is not as indicated in the "TABLE L1", the connector will not couple correctly and the distance measurement will be greater (approx.
  • Page 103 RS 660 - Tuono 660 Electrical system TABLE M - OIL PRESSURE SENSOR • The wiring (1) of the oil pressure sen- sor must pass through the cable grom- met (2) on the control unit support and in the cable grommet (3) on the brake pipe support, left side.
  • Page 104 RS 660 - Tuono 660 Electrical system TABLE M2 - OIL PRESSURE SENSOR • The wiring (1) of the oil pressure sen- sor must pass behind the pipe fitting of the cooling system and after connect- ing the connector to the sensor, lock the wiring with a clamp (5) as indicated.
  • Page 105 RS 660 - Tuono 660 Electrical system TABLE O - LAMBDA PROBES Lambda probe 1 • Insert the lambda probe 1 (1) in its seat, pass the wiring (2) on the right side. • Pass the vehicle-side wiring inside the frame, as indicated, connect the con- nector (3) and fasten it to the clip on the radiator support.
  • Page 106 RS 660 - Tuono 660 Electrical system TABLE A1 - PRE-ASSEMBLY OF THE CABLE GROMMET CLIP ON THE LOWER SADDLE SUPPORT CLOSURE • Position a clamp (3) as shown. TABLE B - BATTERY GROUND AND STARTER MOTOR POSITIVE Pass the wiring as indicated and through the cable grommets Components present: 1) Starter motor positive wiring harness.
  • Page 107 RS 660 - Tuono 660 Electrical system TABLE B1 - BATTERY GROUND AND START- ER MOTOR POSITIVE Pass the wiring as indicated and through the cable grommets Components present: 1) Starter motor positive wiring harness. 2) Battery ground cable wiring harness. TABLE B2 - BATTERY GROUND AND START- ER MOTOR POSITIVE Pass the wiring harness as indicated.
  • Page 108 RS 660 - Tuono 660 Electrical system TABLE B3 - BATTERY GROUND AND START- ER MOTOR POSITIVE Pass the wiring harness as indicated. • The positive wiring (1) of the starter motor is fixed on the upper screw of the starter relay (4).
  • Page 109 RS 660 - Tuono 660 Electrical system TABLE C - CABLE GROMMET UNDER SADDLE SUPPORT Pass the cables as indicated. The main wiring must pass under the inertial plat- form in the special groove on the lower saddle support closure. Components present: 1) Battery.
  • Page 110 RS 660 - Tuono 660 Electrical system TABLE D - BATTERY • The wiring connected to the eyelet (1), must be connected to the positive pole of the battery located on the left side of the vehicle and identified with the plus sign "+".
  • Page 111 RS 660 - Tuono 660 Electrical system TABLE F1 - REAR ABS SENSOR • The wiring (1) of the rear ABS sensor must pass under the rear mudguard and locked to the ABS brake pipe with 3 cable grommets (5). TABLE F2 - REAR ABS SENSOR •...
  • Page 112 RS 660 - Tuono 660 Electrical system TABLE G - LICENSE PLATE SUPPORT • Pass the rear wiring (1) through the three clips (2). • Ensure that the wiring with the red tap- ing goes to the left arrow. TABLE H - REAR SECTION 1) Main wiring harness.
  • Page 113 RS 660 - Tuono 660 Electrical system TABLE H1 - REAR SECTION 7) Connector … 8) Aprilia MIA control unit connector (if present) 9) Connector … 10) Connector … Engine TABLE A - CONTROL UNIT SUPPORT PRE-AS- SEMBLY • Pre-assemble the four cable grommets (1) (2) on the control unit support (3).
  • Page 114 RS 660 - Tuono 660 Electrical system TABLE B - CABLE ARRANGEMENT IN THE CONTROL UNIT ZONE • The connector (1) must be correctly hooked to the control unit (2). TABLE B1 - CABLE ARRANGEMENT IN THE CONTROL UNIT ZONE •...
  • Page 115 RS 660 - Tuono 660 Electrical system TABLE B2 - CABLE ARRANGEMENT IN THE CONTROL UNIT ZONE • Check that the engine oil temperature sensor connector (6) and the gear sen- sor connector (7) are correctly inser- ted. TABLE B3 - CABLE ARRANGEMENT IN THE CONTROL UNIT ZONE •...
  • Page 116 RS 660 - Tuono 660 Electrical system TABLE C - LAMBDA PROBE PASSAGE • Both wiring (1) of the lambda sensors must pass through the cable grommet (2) connected to the secondary air pipe (3). TABLE D - HEAD ZONE PASSAGES 1) Coil connectors (must be attached to the can- ister support).

  • Page 117: General Wiring Diagram

    RS 660 - Tuono 660 Electrical system TABLE E1 - FILTER BOX ZONE PASSAGES • Check the correct insertion of the air pressure sensor connector. General wiring diagram Key: 1. Multiple connectors 2. Horn 3. LH light switch ELE SYS - 117...
  • Page 118 RS 660 - Tuono 660 Electrical system 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 11.Immobilizer antenna 12.Taillight 13.Right rear turn indicator 14.Licence plate light 15.Rear turn indicator LEFT 16.Anti-theft system (not standard)
  • Page 119 RS 660 - Tuono 660 Electrical system 42.Quick Shift switch (UP/DOWN) 43.Neutral/gear sensor 44.Lambda cylinder 2 45.Lambda cylinder 1 46.Injector cylinder 2 47.Injector cylinder 1 48.Coil cylinder 2 49.Coil cylinder 1 50.MAP sensor 51.Motorised throttle valve 52.Intake air temperature sensor 53.Engine water temperature T sensor 54.Engine speed sensor 55.Oil pressure sensor...
  • Page 120 RS 660 - Tuono 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 121 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 122 RS 660 - Tuono 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 123: Control Unit

    RS 660 - Tuono 660 Electrical system Control unit CRANKSHAFT TONE WHEEL ACQUISITION PROCEDURE • Perform the cycle "Reset wheel tooth values" with the PADS diagnostic tool; • Warm the engine to 80°C; • With the gearbox in neutral, the side stand extended and the vehicle com- pletely stationary, throttle up to over 8000 rpm at least three times;...

  • Page 124: Index Of Topics

    INDEX OF TOPICS NGINE...
  • Page 125 RS 660 - Tuono 660 Engine Gearbox OMPLETE GEAR ELECTOR ESMODROMIC Pos. Description Type Quantity Torque Notes Retention plate fixing hex socket 12 Nm (8.85 lbf ft) Pre-impregnated screws Gear selector drum fixing flanged 25 Nm (18.44 lbf ft) hex screw Gear sensor fixing round headed 6 Nm (4.43 lbf ft) screws...
  • Page 126 RS 660 - Tuono 660 Engine Diagram Key: 1. Second gear. 2. Circlip. 3. Toothed thrust washer. 4. Sixth gear. 5. Floating bushing for sixth gear. 6. Toothed thrust washer. 7. O-ring. 8. Third-fourth gear. 9. O-ring. 10.Toothed thrust washer. 11.Fifth gear.

  • Page 127: Gearbox Shafts

    RS 660 - Tuono 660 Engine 20.Toothed thrust washer. 21.Circlip. 22.Fourth gear. 23.Floating bushing for fourth gear. 24.Floating bushing for third gear. 25.Third gear. 26.Toothed thrust washer. 27.Circlip. 28.Sixth gear. 29.Circlip. 30.Floating bushing for second gear. 31.Toothed thrust washer. 32.Second gear. 33.Transmission shaft.
  • Page 128 RS 660 - Tuono 660 Engine • Extract the complete selector shaft (3) from the crankcase. • Unscrew the fixing screw (4) of the in- dex lever. • Remove the fixing screw (4) along with the spring (5) and index lever (6). •...
  • Page 129 RS 660 - Tuono 660 Engine • Remove the fixing screw (9) of the shaft which fastens the forks for the transmission shaft. • Remove the guide shaft (10) from the crankcase and remove both forks (11) of the transmission shaft command. •...
  • Page 130 RS 660 - Tuono 660 Engine • Remove the desmodromic shaft (15) from the crankcase and remove the bearing (16). • Remove the fork (17) from the primary shaft. • Remove the screws (18) and respec- tive countersunk retaining washers (19) of the primary shaft bearing.
  • Page 131 RS 660 - Tuono 660 Engine • Turn the primary shaft (20) outwards and then extract it as indicated. Removing the primary shaft CAUTION FIT NEW CIRCLIPS WHEN REASSEMBLING • After removing the main shaft from its seat on the crankcase, proceed with the disassembly operating from the second gear side.
  • Page 132 RS 660 - Tuono 660 Engine • Remove the toothed thrust washer (3). • Remove the sixth speed gear (4) along with the floating bushing (5). • Remove the toothed thrust washer (6). • Remove the circlip (7) securing the third-fourth gear.
  • Page 133 RS 660 - Tuono 660 Engine • Remove the third-fourth speed gear (8). • Remove the circlip (9) securing the fifth gear. • Remove the toothed thrust washer (10). • Remove the fifth gear (11) along with the floating bushing (12) from the pri- mary shaft (13).
  • Page 134 RS 660 - Tuono 660 Engine • After removing the transmission shaft from its seat on the crankcase, pro- ceed with the disassembly operating from the first gear side. • Remove the thrust washer (1). • Remove the first speed gear (2). •...
  • Page 135 RS 660 - Tuono 660 Engine • Remove the circlip (4) securing the fifth gear. • Remove the fifth speed gear (5). • Remove the circlip (6) securing the fourth gear. • Remove the toothed thrust washer (7). ENG - 135...
  • Page 136 RS 660 - Tuono 660 Engine • Remove the fourth speed gear (8) along with the floating bushing (9). • Remove the third speed gear (10) along with the floating bushing (11). • Remove the toothed thrust washer (12). • Remove the circlip (13) securing the sixth gear.
  • Page 137 RS 660 - Tuono 660 Engine • Remove the circlip (14) securing the second gear. • Remove the toothed thrust washer (15). • Remove the second gear (16) along with the floating bushing (17). • Remove the spacer (18). ENG - 137...
  • Page 138 RS 660 - Tuono 660 Engine • Remove the oil seal (19). • Remove the O-ring (20). • Remove the bearing (21) from the transmission (22). Checking the primary shaft Characteristic Maximum wear limit for selector gear splines 5.3 mm (0.21 in) Minimum wear limit for primary shaft seat, clutch side 24.97 mm (0.98 in)

  • Page 139: Checking The Secondary Shaft

    RS 660 - Tuono 660 Engine Checking the secondary shaft Characteristic Maximum wear limit for selector gear splines 5.3 mm (0.21 in) Minimum wear limit of the pinion side secon- dary shaft seat 29.97 mm (1.18 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in) Checking the desmodromic drum...

  • Page 140: Assembling The Gearbox

    RS 660 - Tuono 660 Engine • Check the gearbox fork's movement, and replace the gearbox forks if it is irregular. Assembling the gearbox To proceed with the assembly of the gearbox, after checking that all the components are intact and do not show wear beyond the limits, proceed as fol- lows: •...
  • Page 141 RS 660 - Tuono 660 Engine • Position the fork (6) on the primary shaft between the third and fourth gear. • Insert the desmodromic shaft (7) through the hole in the crankcase and up to the stop on the bearing. •...
  • Page 142 RS 660 - Tuono 660 Engine • Insert the bearing (10) on the desmo- dromic shaft. • Position the screw (11) with counter- sunk washer (12) and tighten it to the prescribed torque. • After inserting the guide shaft (13) of the forks for the transmission shaft into the crankcase, position the forks (14) making sure that the teeth are in the grooves of the desmodromic shaft.
  • Page 143 RS 660 - Tuono 660 Engine • Position the spring (16) and index lever (17) in the seat on the crankcase. • Secure both using the appropriate screw (18) tightened to the prescribed torque. • Using a screwdriver, move the index lever to allow the drum (19) to be in- serted into the seat on the desmodrom- ic shaft, paying attention to correct...
  • Page 144 RS 660 - Tuono 660 Engine • Position the two screws (22) that fasten the retention plate and tighten them to the prescribed torque. • Position the transmission shaft (23) paying attention to the correct insertion of the forks in it. •...

  • Page 145: Gear Selector

    RS 660 - Tuono 660 Engine Gear selector After removing the gear selector shaft from its seat, it can now be broken down as described: • Remove the retaining plate (1) by slid- ing it off the selector shaft (2) after turning it.

  • Page 146: Removing The Starter Motor

    RS 660 - Tuono 660 Engine LYWHEEL GNITION Pos. Description Type Quantity Torque Notes Starter motor fastening screws M6x35 12 Nm (8.85 lbf ft) Starter ring gear containment plate M6x35 12 Nm (8.85 lbf ft) fastening screw Rotor fastening screw M14x30 195 Nm (143,82 lbf ft) Stator SHC fixing screws...
  • Page 147 RS 660 - Tuono 660 Engine • Remove the four screws (3) that fasten the control unit support. • Remove the clamp (4) of the neutral sensor connector. • Slightly lift the control unit support to allow the oil pressure sensor wiring (6) and the pick-up wiring (7) to be discon- nected from the cable grommets (5).
  • Page 148 RS 660 - Tuono 660 Engine • Disconnect the wiring from the side ca- ble grommet (8) on the control unit sup- port. • Remove the control unit support (9). • Undo the fastening nuts (10) and dis- connect the clutch cable (11) from the lever.
  • Page 149 RS 660 - Tuono 660 Engine • Unscrew the fixing screw of the support bracket (14) of the blow-by pipe and remove it. • Unhook the brake pipes (15) from the support. • Extract the starter motor (16) from its seat and slide it off the left side.

  • Page 150: Installing The Starter Motor

    RS 660 - Tuono 660 Engine • Remove the protective cap (17), un- screw the fastening nut (18) of the wir- ing (19) and remove the starter motor. Installing the starter motor To install the starter motor, proceed as described: •...
  • Page 151 RS 660 - Tuono 660 Engine • Insert the starter motor (4) in its seat and position the two spacers (5) in line with the fixing holes operating from the right side of the vehicle. • Insert the two screws (6) making sure to intercept the spacers and tighten them to the prescribed torque.
  • Page 152 RS 660 - Tuono 660 Engine • Connect the connector (8) to the SAS valve (9) and insert it on the corre- sponding support. • Connect the brake pipes (10) to the support. • Connect the clutch cable (11) to the lever and lock the two adjustment nuts (12).
  • Page 153 RS 660 - Tuono 660 Engine • Insert the control unit support (13) and connect the cables on the cable grom- met (14). • Connect the oil pressure sensor wiring (16) and the pick-up wiring (17) to the cable grommets (15). ENG - 153...
  • Page 154 RS 660 - Tuono 660 Engine • Connect the neutral sensor connector and using a clamp (18) lock it to the support. • Lock the control unit support by tight- ening the four screws (19). ENG - 154...
  • Page 155 RS 660 - Tuono 660 Engine • Insert the control unit (20) in the sup- port and connect the "vehicle" and "en- gine" connectors (21). Removing the idle gear To proceed with the removal of the intermediate gear, it is necessary to first remove the flywheel and the starting ring gear.
  • Page 156 RS 660 - Tuono 660 Engine • Insert the intermediate gear in its seat and rotate it at both ends to check its correct sliding. Removing the starter gear To proceed with the removal of the starting ring gear, it is necessary to first remove the flywheel and the proceed as follows: •...
  • Page 157 RS 660 - Tuono 660 Engine Installing the starter gear To carry out a correct installation of the starting ring gear, proceed as follows: • Generously lubricate the crankshaft with engine oil. • Generously lubricate the inner track of the starting ring gear with engine oil. •...

  • Page 158: Generator Side

    RS 660 - Tuono 660 Engine Generator side LYWHEEL GNITION Pos. Description Type Quantity Torque Notes Starter motor fastening screws M6x35 12 Nm (8.85 lbf ft) Starter ring gear containment plate M6x35 12 Nm (8.85 lbf ft) fastening screw Rotor fastening screw M14x30 195 Nm (143,82 lbf ft) Stator SHC fixing screws...
  • Page 159 RS 660 - Tuono 660 Engine • Remove the 5 screws (2) used to fas- ten the water pump cover. • Remove the water pump cover (3) complete with gasket (4). • Remove the 8 screws (5) used to fas- ten the flywheel cover.
  • Page 160 RS 660 - Tuono 660 Engine • Remove the gasket (7) of the flywheel cover. Rimozione rotore To proceed with the removal of the rotor, proceed as described: • Using the special tool (1) block the ro- tation of the rotor and unscrew the lock- ing screw (2).

  • Page 161: Removing The Stator

    RS 660 - Tuono 660 Engine • Before extracting the rotor (6), position the engine vertically to prevent the spline on the crankshaft from falling in- to the engine itself. • After removing the rotor, remove the spline (7). Removing the stator To proceed with the removal of the stator, proceed as described: •...
  • Page 162 RS 660 - Tuono 660 Engine • Remove the three fixing screws (3) of the stator. • Remove the stator (4). • Disconnect the wiring harness from the cover to complete the removal. Freewheel removal To proceed with the removal of the free wheel, proceed as described: •...

  • Page 163: Checking The Starter Clutch

    RS 660 - Tuono 660 Engine • Separate the free wheel (3) from the flange (2). Flywheel components check - Check that the magnets are in good conditions. - Check that the magnet support cage is not de- formed or broken. Checking the starter clutch Remove the free wheel from its housing and check the rollers for signs of wear.

  • Page 164: Installing The Flywheel

    RS 660 - Tuono 660 Engine Installing the flywheel To proceed with the installation of the rotor, pro- ceed as described: • Position the spline (1) on the crank- shaft. • Insert the rotor (2) on the crankshaft paying attention to align the milling on the rotor, with the spline previously in- serted on the crankshaft.

  • Page 165: Stator Installation

    RS 660 - Tuono 660 Engine Stator installation To proceed with the installation of the stator, pro- ceed as described: • Position the stator (1) on the seat in the flywheel cover. • Screw and tighten the three stator fix- ing screws (2) to the prescribed torque.

  • Page 166: Flywheel Cover Installation

    RS 660 - Tuono 660 Engine • Position the specific tool (6) on the sta- tor to obtain the correct distance of the pick-up. • Push the pick-up at the point indicated, towards the specific tool and tighten the screws (5) to the prescribed torque. Flywheel cover installation To proceed with the installation of the flywheel cover, proceed as described:...
  • Page 167 RS 660 - Tuono 660 Engine • Insert the eight fixing screws (4) of the flywheel cover, screwing them in by hand. • Position the gasket (5) and the cover (6) of the water pump. • Insert the four screws (7) and the screw (8) complete with washer (9) for the fix- ing of the water pump cover.
  • Page 168 RS 660 - Tuono 660 Engine • Insert the inspection cap (10) complete with O-ring on the flywheel cover. • Tighten the inspection cap to the pre- scribed torque. Clutch side LUTCH Pos. Description Type Quantity Torque Notes Clutch fastening nut 175 Nm (129.07 lbf ft) Screws for springs 10 Nm (7.37 lb ft)

  • Page 169: Removing The Clutch Cover

    RS 660 - Tuono 660 Engine Removing the clutch cover To proceed with the removal of the clutch cover, proceed as follows: • Remove the cap/dipstick (1) for check- ing the engine oil level. • Remove the nine screws (2) used to fasten the clutch cover.
  • Page 170 RS 660 - Tuono 660 Engine To remove the components on the cover: • Remove the three screws (5) fixing the blow-by cover. • Remove the blow-by cover (6) and the gasket (7). • Operating in the inside of the cover, re- move the circlip (8).

  • Page 171: Disassembling The Clutch

    RS 660 - Tuono 660 Engine • Remove the oil seal (10). Disassembling the clutch To remove the clutch, proceed as follows: • Carefully and progressively unscrew the three screws (1) securing the thrust plate following the order A-B-C. CAUTION PAY CAREFUL ATTENTION WHILE LOOSENING AND TIGHTENING THE THREE SCREWS (1).
  • Page 172 RS 660 - Tuono 660 Engine • Remove the thrust plate (4). • Extract the clutch push rod (5). • Extract the three retaining springs (6). • Remove the first drive disc (A) with reduced friction material. • Remove the driven disc (B). •...
  • Page 173 RS 660 - Tuono 660 Engine • Open the edges of the retaining washer. • Block clutch hub rotation using the spe- cific tool, unscrew the lock nut (7) and remove it. Specific tooling 9100896 Clutch bell stopper • Remove the stop washer (8). CAUTION DURING REPLACEMENT, USE A NEW STOP WASHER.
  • Page 174 RS 660 - Tuono 660 Engine • Remove the clutch hub (9). • Remove the washer (10). • Remove the clutch housing (11). • Remove the roller cage (12) and the spacer (13). ENG - 174...

  • Page 175: Checking The Clutch Plates

    RS 660 - Tuono 660 Engine • Remove the washer (14). Checking the clutch plates Characteristic Maximum warping of clutch plates (deforma- tion relative to flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch plate sliding teeth 13.5 mm (0.53 in) Minimum wear limit of the complete clutch pack thickness (friction discs + steel discs)
  • Page 176 RS 660 - Tuono 660 Engine Checking the pusher plate Check the thrust plate and the bearing for damage and wear. If necessary, replace the parts. Characteristic Maximum permissible deformation of spring carrier plate pressure face 0.15 mm (0.0059 in) Maximum depth of spring carrier plate 27.3 mm (1.07 in) Checking the clutch hub...

  • Page 177: Assembling The Clutch

    RS 660 - Tuono 660 Engine Assembling the clutch After checking that the discs are within the permit- ted wear limits, refit by repeating the operations described for removal but in the reverse order: • Insert the washer (1) on the primary shaft.
  • Page 178 RS 660 - Tuono 660 Engine • Insert the clutch hub (6). • Insert a new retaining washer (7) pay- ing careful attention to ensure the cor- rect assembly direction. • The edge (A) must match the machin- ing (A) on the clutch hub. CAUTION AT EACH DISASSEMBLY / ASSEMBLY OF THE CLUTCH, THE RETAINING WASHER MUST BE REPLACED.
  • Page 179 RS 660 - Tuono 660 Engine • Insert the nitrided drive disc (E). • Insert the five drive discs (D) alternating with the five driven discs (C). • Insert the second drive disc (A) with reduced friction material.. • Insert the driven disc (B). •...
  • Page 180 RS 660 - Tuono 660 Engine • Centre the last driven disc in relation to the housing to facilitate positioning of the thrust plate. • The thrust plate, if inserted correctly, will have the teeth that mesh with the drive disc and will therefore not be placed on top of it.

  • Page 181: Installing The Clutch Cover

    RS 660 - Tuono 660 Engine • Insert the thrust plate (13) complete with the three lock screws (14). • Carefully and progressively, screw down the three screws securing the thrust plate following the order A-B-C. CAUTION PAY CAREFUL ATTENTION TO TIGHTENING THE THREE SCREWS.
  • Page 182 RS 660 - Tuono 660 Engine • Place the cover (2) of the blow-by sys- tem complete with the three fixing screws (3) and tighten them to the specified torque. • Place the oil seal (4) inside of the clutch cover and fully insert it with the special tool.
  • Page 183 RS 660 - Tuono 660 Engine • Using a hair dryer, heat the housing seat of the lower clutch control shaft bearing. • Partially insert the clutch control shaft (7) and position the bearing (8) on the shaft. • Using a rubber hammer act on the clutch control shaft and fully insert the lower bearing.
  • Page 184 RS 660 - Tuono 660 Engine • Fully insert the upper bearing (9) using the specific tool after having inserted it on the clutch control shaft. Specific tooling 021042Y Oil seal and clutch shaft bearing and gear shaft punch • Lubricate the inside of the oil seal (10) and insert it on the clutch control shaft.
  • Page 185 Engine • Position the gasket (12) on the crank- case. • The use of the pins (13) Aprilia cod. AP8121222 is recommended to facili- tate the positioning of the cover. • Rotate the clutch rod bringing the toothing to the left as indicated.

  • Page 186: Crankshaft Check

    RS 660 - Tuono 660 Engine • After inserting the metal clamp (16) into the blow-by pipe (17), connect it and close the clamp. • Position the bracket (18) and insert the missing screw (19) fixing the cover and tighten it to the specified torque. •...

  • Page 187: Piston-Cylinder Coupling

    RS 660 - Tuono 660 Engine Balancing countershaft check There are two dimensional classes for the counter- shaft pins: F and G Characteristic Maximum counter-shaft axial clearance after closing the crankcase 0,40 - 0,18 mm (0.0157 - 0.0070 in) Connecting rod check Characteristic Maximum wear limit of the connecting rod small end 17.03 mm (0.6705 in)
  • Page 188 RS 660 - Tuono 660 Engine Selecting connecting rods SELECTING CRANKSHAFTS AND CONNECTING RODS ACCORDING TO BALANCING CLASS crankshafts and connecting rods have been introduced which are matched with each other in relation to their balancing class. The class is easily identifiable as it is marked on the component itself. Key: 1) Primary side main journal class;...

  • Page 189: Connecting Rod Bushings

    RS 660 - Tuono 660 Engine the bushings for connecting the connecting rods to the crankshaft can be defined according to the following table: CONNECTING RODS - CRANKSHAFT COUPLING Crank pin Connecting rod class Clearance Connecting rod class Clearance dimensional class BLUE + YELLOW 0.053 - 0.026 mm YELLOW + YELLOW...
  • Page 190 RS 660 - Tuono 660 Engine Crankshaft class The main journal classes useful for the crankcase- crankshaft coupling are stamped on the crankshaft (see figure). Key: 1) Primary side main journal class; 2) Centre main journal class; 3) Flywheel side main journal class; Crankshaft-crankcase coupling CRANKSHAFT-CRANKCASE COUPLING Crankcase Class A...
  • Page 191 RS 660 - Tuono 660 Engine Countershaft category The main journal classes and the dimensional classes useful for the countershaft crankcase cou- pling are stamped on the countershaft (see figure). Key: 1) Primary side; 2) Central; 3) Flywheel side. Countershaft-crankcase coupling COUNTERSHAFT-CRANKCASE COUPLING Crankcase Class F Crankcase Class G...
  • Page 192 RS 660 - Tuono 660 Engine Head and timing EAD COVER Pos. Description Type Quantity Torque Notes Spark plugs 12 Nm (8.85 lbf ft) Head cover fastening screws 10 Nm (7.38 lbf ft) TE flanged coil fixing screw M6x16 12 Nm (8.85 lbf ft) ENG - 192...

  • Page 193: Removing The Head Cover

    RS 660 - Tuono 660 Engine ALVES Pos. Description Type Quantity Torque Notes Cam tower fixing screws 11 Nm (8.11 lbf ft) Water temperature sensor 20 Nm (14.75 lbf ft) Thermostat cover flanged hex fixing 6 Nm (4.43 lbf ft) screw Secondary air cover fixing screws M5x16...

  • Page 194: Removing The Cylinder Head

    RS 660 - Tuono 660 Engine • Remove the three fixing screws (5) of the membrane cover plate. • Remove the cover plate (6) of the membrane. • Remove the membrane (7). Removing the cylinder head To proceed with the removal of the head, it is nec- essary to first remove the timing system complete with the cam tower, camshafts and timing chain.

  • Page 195: Cylinder Head

    RS 660 - Tuono 660 Engine • Remove the washers (3) in corre- spondence with the stud bolts. • Remove the head (4). • Remove the gasket (4). Cylinder head Removing the overhead camshaft To proceed with the removal of the camshafts it is necessary to rotate the crankshaft so that the valves are not under tension and after removing the head cover, proceed as described:...

  • Page 196: Removing The Valves

    RS 660 - Tuono 660 Engine • Remove the cam tower complete with plate. • After removing the chain tensioner, proceed with the removal of the intake camshaft, removing the timing chain from the gear on the shaft itself. • After removing the chain tensioner, proceed with the removal of the ex- haust camshaft, removing the timing...
  • Page 197 RS 660 - Tuono 660 Engine • Using a magnet, remove the bucket tappet (1). • Using a magnet, remove the calibrated pad (2). • Position the specific tool as indicated on the intake valve. Specific tooling AP8140179 Valve fitting/removal support 020853Y Compresses intake valve springs ENG - 197...
  • Page 198 RS 660 - Tuono 660 Engine • Compress the spring and using a mag- net remove the two half-cotters (3) holding the cup. • Remove the upper cup (4). • Remove the two springs (5) of the in- take valve, marked in orange for the external one and blue for the internal one.
  • Page 199 RS 660 - Tuono 660 Engine • Remove the sealing ring (7). • Remove the lower cup (8). EXHAUST VALVES CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE EXHAUST VALVE BUT ARE VALID FOR BOTH. • Using a magnet, remove the bucket tappet (9).
  • Page 200 RS 660 - Tuono 660 Engine • Position the specific tool as indicated on the exhaust valve. Specific tooling AP8140179 Valve fitting/removal support 020853Y Compresses intake valve springs • Compress the spring and using a mag- net remove the two half-cotters (11) holding the cup.

  • Page 201: Installing The Valves

    RS 660 - Tuono 660 Engine • Remove the spring (13) of the exhaust valve, marked in yellow. • Remove the valve (14). • Remove the sealing ring (15). • Remove the lower cup (16). Installing the valves To proceed with the installation of the valve, proceed as described: •...
  • Page 202 RS 660 - Tuono 660 Engine CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE INTAKE VALVE BUT ARE VALID FOR BOTH. • Position the lower cap (1). • Install the sealing ring (2). • Insert the valve (3). • Insert the two springs (4) of the intake valve, marked in orange for the exter- nal one and blue for the internal one.
  • Page 203 RS 660 - Tuono 660 Engine • Position the upper cup (5). • Position the specific tool as indicated on the intake valve. Specific tooling AP8140179 Valve fitting/removal support 020853Y Compresses intake valve springs • Compress the springs and using a magnet position the two half-cotters (6) holding the cup.
  • Page 204 RS 660 - Tuono 660 Engine • Using a punch with a rubber mallet, check that the valve is not blocked. • Position the calibrated pad (7). • Position the bucket tappet (8). EXHAUST VALVES CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE EXHAUST VALVE BUT ARE VALID FOR BOTH.
  • Page 205 RS 660 - Tuono 660 Engine • Install the sealing ring (10). • Insert the valve (11). • Insert the spring (12) of the exhaust valve, marked in yellow. CAUTION THE SPRING MUST BE POSITIONED WITH THE MORE COMPRESSED PART OF THE SPIRALS FACING THE HEAD •...
  • Page 206 RS 660 - Tuono 660 Engine • Position the specific tool as indicated on the exhaust valve. Specific tooling AP8140179 Valve fitting/removal support 020853Y Compresses intake valve springs • Compress the spring and using a mag- net position the two half-cotters (14) holding the cup.
  • Page 207 RS 660 - Tuono 660 Engine • Position the calibrated pad (15). CAUTION THE CALIBRATED PAD MUST BE ASSEMBLED KEEPING THE PRINTING OF THE THICKNESS UPWARDS. • Position the bucket tappet (16). Installing the overhead camshaft The camshaft refitting procedure is described in the "Timing" section. ENG - 207...
  • Page 208 RS 660 - Tuono 660 Engine Timing ALVES Pos. Description Type Quantity Torque Notes Cam tower fixing screws 11 Nm (8.11 lbf ft) Water temperature sensor 20 Nm (14.75 lbf ft) Thermostat cover flanged hex fixing 6 Nm (4.43 lbf ft) screw Secondary air cover fixing screws M5x16...
  • Page 209 RS 660 - Tuono 660 Engine • Remove the copper washer (2). • Remove the special screw (3). • Remove the metal washer (4). • Remove the chain tensioner (5) com- plete with O-ring (6). ENG - 209...

  • Page 210: Chain Removal

    RS 660 - Tuono 660 Engine Chain removal To proceed with the removal of the timing chain, proceed as described: • Remove the chain from the timing gear on the crankshaft. • Remove the chain from the head. Removing the chain sliders To proceed with the removal of the slider, it is nec- essary to remove the complete head and then proceed as described:...
  • Page 211 RS 660 - Tuono 660 Engine • Remove the mobile slider (3). Installing the chain tensioner To proceed with the installation of the chain ten- sioner, proceed as described: • After verifying correct operation, use a rubber hammer to arm the chain ten- sioner.

  • Page 212: Cam Timing

    RS 660 - Tuono 660 Engine • Tighten the fitting to the specified tor- que. • Disarm the chain tensioner by using a punch through the hole in the fitting. • Insert the plug (5) complete with cop- per washer (6). •...
  • Page 213 RS 660 - Tuono 660 Engine IF TIMING IS FORESEEN FOLLOWING THE VALVE CLEARANCE ADJUSTMENT OPERATION (WITH THE ENGINE ASSEMBLED ON THE VEHICLE), REFER TO THE PROCEDURE DESCRIBED IN THE "MAINTENANCE" CHAPTER IN PARAGRAPH "TIMING CHECK". To carry out engine timing proceed as described: •...
  • Page 214 RS 660 - Tuono 660 Engine • Position the cam tower (3). • Position the ten fixing screws (4) of the cam tower with the exception of the two screws which also fix the plate with the chain slider. • Tighten the screws to the prescribed torque following the indicated se- quence.
  • Page 215 RS 660 - Tuono 660 Engine • Insert and hand tighten one screw (7) of the timing gear onto the exhaust camshaft. • Position the specific tool on the intake camshaft as indicated. • Using the specific tool (8) rotate the in- take camshaft to intercept the insertion point of the third pin (9) on the cam tower.
  • Page 216 RS 660 - Tuono 660 Engine • Using a punch, simulate the tension of the transmission chain and check that the holes of the fixing screws of the timing gears are centred with respect to the slotted holes of the gears them- selves.
  • Page 217 RS 660 - Tuono 660 Engine • Insert the chain tensioner (13) com- plete with O-Ring (14). • Insert the special screw (15) complete with metal washer (16). • Tighten the fitting to the specified tor- que. • Disarm the chain tensioner by using a punch through the hole in the fitting.
  • Page 218 RS 660 - Tuono 660 Engine • Insert the plug (17) complete with cop- per washer (18). • Tighten the plug to the prescribed tor- que. • After correctly inserting the chain ten- sioner and tensioning the timing chain, insert the two missing screws in the timing gears, tightening them all to the prescribed torque.

  • Page 219: Installing The Cylinder Head

    RS 660 - Tuono 660 Engine Cylinder-piston assembly RANKSHAFT Pos. Description Type Quantity Torque Notes Connecting rod screws 1) 15 Nm (11,06 lbf ft) - Lubricate with Pankl 2) 20 Nm+110° (14,75 lbf ft+110°) Installing the cylinder head To proceed with the installation of the head, pro- ceed as described: •...
  • Page 220 RS 660 - Tuono 660 Engine • Insert the head (2). • Insert the washers (3) in correspond- ence with the stud bolts (lubricate with MOLYKOTE G-RAPID PLUS). • Position the six head fixing nuts and tighten them to the prescribed torque in the order indicated.
  • Page 221 RS 660 - Tuono 660 Engine Installing the head cover For the installation of the head cover, proceed as described: • Position the membrane (1). • Position the metal plate (2). • Insert and tighten the fastening screws (3) of the metal plate to the prescribed torque.

  • Page 222: Crankcase - Crankshaft

    RS 660 - Tuono 660 Engine • Fit the cover (5). • Position the four fixing screws (6) of the head cover and the relative damper pads (7). • Tighten the four fixing screws of the head cover to the prescribed torque. Crankcase - crankshaft ENG - 222...
  • Page 223 RS 660 - Tuono 660 Engine RANKCASE Pos. Description Type Quantity Torque Notes Crankcase halves mating screws M10x65 1) 15 Nm (11,06 lbf ft) - Lubricate with oil 2) 20 Nm+30° (14,75 lbf ft+30°) - 3) 30° (result- ing torque approx 65 Nm (47,94 lbf ft) Crankcase halves mating threaded M8x45...
  • Page 224 RS 660 - Tuono 660 Engine • Remove the thirteen M8 screws (4) and recover the copper washers where present. • Remove the six M10 screws (5). • Remove the lower crankcase (6). ENG - 224...

  • Page 225: Removing The Countershaft

    RS 660 - Tuono 660 Engine Removing the countershaft To proceed with the removal of the counter-shaft it is necessary to remove the upper crankcase, then remove it from its seat. Refitting the crankcase halves To proceed with the coupling of the crankcases after having inserted all gearbox components, the crankshaft complete with connecting rods/pistons, proceed as described:...
  • Page 226 RS 660 - Tuono 660 Engine • Apply a layer of threebond at the points indicated on the lower crankcase. • Position the lower crankcase (2) on the upper crankcase. • Tighten the six internal M10 screws, the M8 screws and the M6 screws crosswise to the prescribed torque, following the alphabetical order.

  • Page 227: Oil Pump

    RS 660 - Tuono 660 Engine Lubrication UBRICATION Pos. Description Type Quantity Torque Notes Oil filter 15 Nm (11.06 lbf ft) Oil filter joint 28.5 Nm (21.02 lbf ft) Oil pressure sensor 13 Nm (9.59 lbf ft) Crankcase cap 20 Nm (14.75 lbf ft) Oil pressure regulation valve 42 Nm (30.98 lbf ft) Drainage plug...
  • Page 228 RS 660 - Tuono 660 Engine • Remove the gear fixing screw (2) and recover the spring washer (3). • Remove the gear (1) of the oil pump paying attention to recover the pin (4). • Undo the two screws used to fasten the oil pump (5) and remove them.
  • Page 229 RS 660 - Tuono 660 Engine Installing To proceed with the installation of the oil pump, proceed as described: • Position the oil pump (1) in its seat, checking the alignment with the holes in the crankcase. • Insert and tighten the two oil pump fix- ing screws (2) to the prescribed torque.
  • Page 230 RS 660 - Tuono 660 Engine • Tighten the fixing screw of the oil pump to the prescribed torque. Oil sump Removing the oil sump To proceed with the disassembly of the oil sump, proceed as described: • Remove the ten fixing screws (1) of the oil sump.
  • Page 231 RS 660 - Tuono 660 Engine • Extract the rose pipe (4) and remove it at the same time as the gasket (5). • Check the presence of the O-ring on the rose pipe and that it has not remained in its seat. Refitting the oil sump To proceed with the assembly of the oil sump, pro- ceed as described:...
  • Page 232 RS 660 - Tuono 660 Engine • Insert the ten screws (6) and tighten them to the specified torque. • If removed, insert the engine oil drain plug and tighten it to the prescribed torque. Pressure reducer valve To proceed with the disassembly of the overpres- sure valve it is necessary to first remove the oil sump and then proceed as described: •...

  • Page 233: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 234 RS 660 - Tuono 660 Power supply P SUPP - 234...
  • Page 235 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 236 RS 660 - Tuono 660 Suspensions Front Handlebar ANDLEBAR ONTROLS Pos. Description Type Quantity Torque Notes Domed head torx screw fastening M10x55 46 Nm (33.92 lbf ft) semi-handlebar SHC screw fastening anti-vibration M5x50 ... Nm (... lb ft) weight Right hand light switches fixing 4 Nm (2.95 lb ft) screw Left hand light switches fixing screw...
  • Page 237 RS 660 - Tuono 660 Suspensions • Loosen the locking screw (3) of the throttle control. • Loosen the locking screw (4) of the light switch. • After unscrewing the locking screws (5) of the U-bolt (6), move the brake pump away and secure it to the top fairing, so that the oil inside the filling tank remains horizontal.
  • Page 238 RS 660 - Tuono 660 Suspensions • Slide off the light switch and the throttle control from the semi-handlebar and remove it. LEFT SEMI-HANDLEBAR: • Unscrew the fixing screw (1) and re- move the anti-vibration weight (2). • Using compressed air helps to easier remove the hand grip (3) from the semi-handlebar.
  • Page 239 RS 660 - Tuono 660 Suspensions • Loosen the locking screw (5) of the clutch control. • Keeping the semi-handlebar (6) still, remove the locking screw (7). • Slide off the light switch and the clutch control from the semi-handlebar and remove it.

  • Page 240: Front Fork

    RS 660 - Tuono 660 Suspensions Front fork RONT FORK Pos. Description Type Quantity Torque Notes 22.5 Nm (16.60 lbf ft) Cap locknut 15 Nm (11.06 lbf ft) Plunger fastening screw 22.5 Nm (16.60 lbf ft) Wheel pin safety locking screw 18 Nm (13.27 lbf ft) ABS sensor screw 6 Nm (4.42 lb ft)

  • Page 241: Removing The Fork Legs

    RS 660 - Tuono 660 Suspensions TO COUNT THE NUMBER OF CLICKS AND/OR REVOLU- TIONS OF ADJUSTMENT SETTINGS ALWAYS START FROM THE MOST RIGID SETTING (WHOLE CLOCKWISE ROTATION OF THE SETTING). STANDARD ADJUSTMENT FOR ROAD USE Specification Desc./Quantity Rebound damping adjustment, screw (1) Unscrew (**) 18 clicks from fully closed (*) Spring pre-loading, nut (2) Fully loosened (**)
  • Page 242 RS 660 - Tuono 660 Suspensions (IF AVAILABLE) • Remove the internal fixing screw (2) of the ABS cable grommet. • Remove the fixing clamp (3) of the ABS wiring harness. • After removing the fixing screw of the ABS sensor (4), extract it internally from the stanchion as indicated.

  • Page 243: Draining Oil

    RS 660 - Tuono 660 Suspensions • Use a support to prevent the fork from falling as a result of unscrewing the fix- ing screw (6) on the upper triple clamp. • Extract and remove the stanchion (7). • During reassembly, pay attention to the adjustment of the stanchion protrusion, referring to the "Adjustment"...
  • Page 244 RS 660 - Tuono 660 Suspensions • Set the spring pre-loading to minimum, by completely unscrewing the adjuster (2). • Loosen the cap (3). • Lower the sleeve completely and using the specific tool (4), fixed to the pre- loading pipe (5), compress the spring. •...
  • Page 245 RS 660 - Tuono 660 Suspensions • Unscrew and remove the cap (8). • Remove the upper plate (9). • Release the pressure on the tool (4) and remove it together with the pre- load pipe (5). • Remove the spring (11) allowing the oil inside the stanchion to drip out.

  • Page 246: Disassembling The Fork

    RS 660 - Tuono 660 Suspensions • 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. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.

  • Page 247: Checking The Components

    RS 660 - Tuono 660 Suspensions • Observing the indicated sequence, ex- tract and remove the slider bushing (14), the guide bushing (15), the ring (16), the oil seal (17), the seeger ring (13) and the dust guard (12). • Loosen the screw on the foot of the fork and using the special Kajaba tool, unscrew the plunger without removing it.
  • Page 248 RS 660 - Tuono 660 Suspensions CAUTION A BENT STANCHION SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAKENED MAKING THE VEHICLE DANGEROUS TO USE. Characteristic Bending limit: 0.2 mm (0.00787 in) 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.
  • Page 249 RS 660 - Tuono 660 Suspensions • Insert the seeger ring (2). • Insert the oil seal (3). • Insert the ring (4). • Insert the guide bush (5). SUSP - 249...
  • Page 250 RS 660 - Tuono 660 Suspensions • Insert the sliding bush (6). • Insert the plunger (7). • Insert the screw (8) complete with cop- per washer (9) to secure the plunger on the foot of the fork. • Using the special Kajaba tool (10), manually screw the plunger while keep the screw on the foot of the fork still.

  • Page 251: Filling Oil

    RS 660 - Tuono 660 Suspensions • Block the sleeve in the vice with the special protective jaws and insert the complete stanchion. Specific tooling AP8140149 Guard for assembly operations • Using the special tool complete with striking weight, insert the oil seal cor- rectly in its seat.
  • Page 252 RS 660 - Tuono 660 Suspensions • Place the sleeve upright in a vice fitted with protection shoes. • Compress the sleeve in the stanchion. Place a support under the stanchion in order to leave it compressed. • Pour part of the fork oil into the sleeve. •...
  • Page 253 RS 660 - Tuono 660 Suspensions • Insert the pre-load pipe (12) complete with special tool (13), making sure that it is aligned correctly. The narrower part must be inserted into the spring. Specific tooling 020888S Pre-load tube clamp • After positioning the support rod (14) of the plunger, with the help of a second worker, raise the plunger to allow the...
  • Page 254 RS 660 - Tuono 660 Suspensions • Screw the cap (17) onto the plunger as far as it will go. CAUTION CHECK THE O-RING PRESENT ON THE FILLING CAP AND REPLACE IF DAMAGED. • Ensure that the cap (17) cannot rotate, and then tighten the nut (18).
  • Page 255 RS 660 - Tuono 660 Suspensions Removal To remove the upper triple clamp it is necessary to first remove the semi-handlebars complete with grips, throttle control, light switches, clutch lever and front brake master cylinder. • To perform this operation after remov- ing the left hand grip, the front brake master cylinder, loosening the fixing screws of the light switches, the throttle...
  • Page 256 RS 660 - Tuono 660 Suspensions • Extract the upper triple clamp (6) from the pin. Steering bottom yoke Removing To remove the lower triple clamp it is necessary to previously remove the front wheel complete with mudguard, the upper triple clamp, the stanchions and the lower fairings to position a centre stand on the sump.
  • Page 257 RS 660 - Tuono 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 258 RS 660 - Tuono 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 259: Steering Bearing

    RS 660 - Tuono 660 Suspensions • Insert the safety plate (5). Steering bearing Adjusting play • 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 260 RS 660 - Tuono 660 Suspensions • Remove the washer (3). • After having adequately protected the instrument cluster, remove the plate (4) complete with semi-handlebars and rest it on the instrument cluster sup- port. • Remove the safety plate, unscrew the counter-lock ring, remove the rubber shim and then unscrew the lower ring nut using the special tool in order to re-...
  • Page 261 RS 660 - Tuono 660 Suspensions Disassembling Place the motorcycle on a lifting jack in corre- spondence of the oil sump and secure it with straps to the footrest. Remove the upper triple clamp, front wheel, mud- guard and stanchions beforehand. Then proceed as described: •...
  • Page 262 RS 660 - Tuono 660 Suspensions • Remove the complete lower triple clamp (5). • Remove the dust seal ring (6). • Remove the bearing upper seat (7). • Remove the inner ring of the bearing (8) complete with balls. SUSP - 262...
  • Page 263 RS 660 - Tuono 660 Suspensions • Remove the lower seat of the bearing (9) using a standard bearing extractor • Remove the dust seal ring (10). 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...
  • Page 264 RS 660 - Tuono 660 Suspensions • Remove the dust seal ring (15). Assembling To assemble the steering assembly, proceed as described: • Place the dust cover (1) on the steering headstock. • Insert the lower seat of the bearing (2) and the inner ring of the bearing (3) complete with balls, sprinkling them with grease...
  • Page 265 RS 660 - Tuono 660 Suspensions • Insert the complete triple clamp (6) into the headstock. • Supporting the lower triple clamp, in- sert the inner ring of the bearing (7) complete with balls on the headstock and lubricate it. •...
  • Page 266 RS 660 - Tuono 660 Suspensions • Supporting the lower triple clamp, in- sert the ring nut (10) on the headstock and tighten it fully by hand. • Using the special tool, pre-tighten the ring nut to ... Nm (... lbf ft) and then tighten it to ...

  • Page 267: Shock Absorbers

    RS 660 - Tuono 660 Suspensions Shock absorbers HOCK ABSORBER Pos. Description Type Quantity Torque Notes Flanged, self-locking shock absorber 50 Nm (36.87 lb ft) fastening nuts SUSP - 267...
  • Page 268 RS 660 - Tuono 660 Suspensions Adjusting The rear suspension consists of a spring-shock absorber unit connected to the frame by uniball joints. To adjust the setting, the shock absorber has an adjuster screw (1) for adjusting the rebound hy- draulic braking, a ring nut for adjusting the spring pre-load (2) and a locking ring nut (3).
  • Page 269 IF THE SPRING PRE-LOADING IS INCREASED, IT IS NEC- ESSARY TO INCREASE THE REBOUND DAMPING AC- CORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING. IF NECESSARY, CONTACT AN OFFICIAL APRILIA DEAL- ER. TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED.
  • Page 270 RS 660 - Tuono 660 Suspensions Removing To remove the shock absorber, it is necessary to remove the weight from the shock absorber using a lifting jack, fastening the motorcycle as indicated. • After removing the crankcase cover and the rear mudguard, keeping the screw (2) still, unscrew the nut (3) and remove the screw.
  • Page 271 RS 660 - Tuono 660 Suspensions • Take care in recovering the 4 bushings (7). Installing To install the shock absorber, proceed as descri- bed: • If removed during disassembly, repo- sition the T-shaped bushes (1), both on the swingarm and on the frame. •...
  • Page 272 RS 660 - Tuono 660 Suspensions • After inserting the screw (4), keeping it still, and tighten the nut (5) to the pre- scribed torque. • After inserting the screw (6), keeping it still, and tighten the nut (7) to the pre- scribed torque.

  • Page 273: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS...

  • Page 274: Front Wheel

    RS 660 - Tuono 660 Chassis Wheels Front wheel RONT WHEEL Pos. Description Type Quantity Torque Notes Wheel axle 65 Nm (47.94 lb ft) Front brake disc flanged hex fixing M8x20 25 Nm (18.43 lb ft) screw 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:...
  • Page 275 RS 660 - Tuono 660 Chassis • Remove the wheel pin (2). • Keeping the wheel raised, extract the wheel pin (2). • Remove the complete wheel (3). • Remove the spacer (4) on the right side of the wheel. CHAS - 275...
  • Page 276 RS 660 - Tuono 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 (5). • Using special pliers, remove the circlip (6).
  • Page 277 RS 660 - Tuono 660 Chassis • Insert the nut (E) and screw it keeping the pin (A) still, to extract the bearing (7). • Remove the bearing (7). NOTE REPEAT THE OPERATION DESCRIBED ABOVE, TO REMOVE THE BEARING ON THE OPPOSITE SIDE OF THE WHEEL.
  • Page 278 RS 660 - Tuono 660 Chassis • Remove the tone wheel (10) (if present). Installing To mount the front wheel, proceed as follows: INSTALLATION OF EXTERNAL COMPONENTS • Position the tone wheel (1) (if present) on the rim. • Tighten the six fastener screws of the tone wheel to the specified torque / brake disc, as shown.
  • Page 279 RS 660 - Tuono 660 Chassis • Using the appropriate punch, insert the bearing as far as it will go. Specific tooling 020376Y Adaptor handle 020358Y 37 x 40 mm Adaptor • Fit the left oil seal (3). • Using the appropriate punch, insert the oil seal as far as it will go.
  • Page 280 RS 660 - Tuono 660 Chassis • Fit the bearing (5). • Using the appropriate punch, insert the bearing as far as it will go. Specific tooling 020376Y Adaptor handle 020358Y 37 x 40 mm Adaptor • Insert the circlip (6). •...
  • Page 281 RS 660 - Tuono 660 Chassis • Using the appropriate punch, insert the oil seal as far as it will go. Specific tooling 020376Y Adaptor handle 020358Y 37 x 40 mm Adaptor • Fit the spacer (8). • Position the wheel (9) and insert the pin (10).

  • Page 282: Rear Wheel

    RS 660 - Tuono 660 Chassis • Tighten the screw on the right stan- chion clamp to the specified torque. • Rotate the wheel a few times to check that it does not stick. Rear wheel EAR WHEEL Pos. Description Type Quantity Torque...
  • Page 283 RS 660 - Tuono 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 284 RS 660 - Tuono 660 Chassis • Supporting the wheel and working from the right side, remove the wheel pin (5) complete with both chain tensioners (6). • Remove the chain (7) from the sprock- et and remove the rear wheel (8). REMOVAL OF EXTERNAL WHEEL COMPO- NENTS To proceed with the removal of the external wheel...
  • Page 285 RS 660 - Tuono 660 Chassis • Remove the five fixing screws (11) of the tone wheel / front disc. • Remove the tone wheel (12). REMOVAL OF INTERNAL WHEEL COMPO- NENTS To proceed with the removal of the internal wheel components, proceed as described: Using a generic puller, extract the bearing as fol- lows:...
  • Page 286 RS 660 - Tuono 660 Chassis • Insert the nut (E) and screw it keeping the pin (A) still, to extract the bearing (13). • Remove the bearing (13). • Remove the internal spacer (14). • Working on the right side of the wheel, remove the spacer (15).
  • Page 287 RS 660 - Tuono 660 Chassis • Remove the oil seal (16). • Remove the seeger ring (17). • Remove the bearing following the procedure described above. REAR SPROCKET SUPPORT DISASSEMBLY • Having removed the sprocket support from the wheel, remove the external spacer (18).
  • Page 288 RS 660 - Tuono 660 Chassis • Block the sprocket support in a vice provided with protective jaws and re- move the five fixing screws (20) of the chain/sprocket guard. • Remove the five spring washers (21). • Remove the chain guard (22). •...
  • Page 289 RS 660 - Tuono 660 Chassis • Remove the oil seal (24). • Remove the seeger ring (25). • Following the procedure described above for bearing removal, and re- move the bearing (26) present in the sprocket support. Installing To mount the rear wheel, proceed as described: REAR SPROCKET SUPPORT ASSEMBLY •...
  • Page 290 RS 660 - Tuono 660 Chassis • Using the appropriate punch, insert the bearing as far as it will go. Specific tooling 020376Y Adaptor handle 020655S Adaptor 62x68 mm • Insert the circlip (3). • Position the oil seal (4) on the sprocket support.
  • Page 291 RS 660 - Tuono 660 Chassis • Position the sprocket (5) on the sprock- et support. • Position the chain guard (6) on the sprocket support. • Position the five spring washers (7) on the sprocket support. • Tighten the five fastening nuts of the chain/sprocket guard to the prescribed torque, as indicated.
  • Page 292 RS 660 - Tuono 660 Chassis • Insert the internal spacer (8). • Insert the external spacer (9). INSTALLATION OF INTERNAL WHEEL COMPONENTS To proceed with the installation of the internal wheel components, proceed as described: • Fit the bearing (10) in the seat. •...
  • Page 293 RS 660 - Tuono 660 Chassis • Fit the internal spacer (11) from the op- posite side. • Fit the bearing (13) in the seat. • Using the appropriate punch, insert the bearing as far as it will go. Specific tooling 020376Y Adaptor handle 020359S 42 x 47 mm Adaptor INSTALLATION OF EXTERNAL WHEEL COM-...
  • Page 294 RS 660 - Tuono 660 Chassis • Position the five fixing screws of the phonic wheel / brake disc and tighten them to the prescribed torque in the or- der indicated. • Position the flexible coupling rubber in- serts (16) on the rim. •...
  • Page 295 RS 660 - Tuono 660 Chassis • Working from the right side of the mo- torcycle, lift the wheel and insert the pin (20) complete with the chain tensioner (21). • Insert the left chain tensioner (22). • Insert the washer (23). •...
  • Page 296 RS 660 - Tuono 660 Chassis • Working from both sides, act on the adjustment register (25) to bring the chain to the correct tension and tighten the locking nuts (26). • Check that the vertical deflection of the bottom section of the chain, measured at a distance of 250 mm (9.84 in) from the centre of the rear wheel axle (along imaginary line between centres of front...

  • Page 297: Swinging Arm

    RS 660 - Tuono 660 Chassis Swinging arm WINGARM Pos. Description Type Quantity Torque Notes Swingarm pivot bolt self-locking nut 110 Nm (4.33 lbf ft) Chain feeder shoe SHC flanged fas- M5x16 2 Nm (1.47 lb ft) tening screws Removing Place the motorcycle on the central stand and se- cure it using a lifting jack, in order to be able to keep the rear part raised when removing the...
  • Page 298 RS 660 - Tuono 660 Chassis • Remove the nut (2), with its washer, which fixes the left rider footrest sup- port to the swingarm. • Remove the complete footrest support (3) from the swingarm pin. • Remove the flat washer (4) from the swingarm pin.
  • Page 299 RS 660 - Tuono 660 Chassis • Release the brake calliper complete with support from the guide on the swingarm. • Remove the screw (6) complete with nut (7) that blocks the shock absorber to the swingarm. • Using rubber bands, support the shock absorber (8) to help the subsequent re- moval of the swingarm.
  • Page 300 RS 660 - Tuono 660 Chassis • Remove the swingarm pin (10) from the right side of the vehicle, taking care to recover the spacer (11) which is lo- cated between the swingarm and the right rider footrest support. • Remove the complete swingarm (12).

  • Page 301: Left Side

    RS 660 - Tuono 660 Chassis CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED, DAMAGED, CRACKED AND/OR DENTED. REPLACE ALL DAMAGED COMPONENTS. ROLLER CASINGS Turn the roller casings manually; they must rotate smoothly, continuously and silently. There must be no axial clearance. Replace the roller casings that present these problems.
  • Page 302 RS 660 - Tuono 660 Chassis • Position the 4 gaskets (4) on the swing- arm to the level of the internal machin- ing as shown in the image. • Place the complete swingarm (5) in its seat. CHAS - 302...
  • Page 303 RS 660 - Tuono 660 Chassis • Working from the right side of the ve- hicle, insert the swingarm pin (6) and the spacer (7) making sure of the cor- rect orientation. • The machined part must be facing the swingarm.
  • Page 304 RS 660 - Tuono 660 Chassis • Position the cable gland (12) that fas- tens the ABS sensor wiring harness and the rear brake hose to the frame. • Insert the flat washer (13) on the swing- arm pin with the machined part facing the swingarm itself.
  • Page 305 RS 660 - Tuono 660 Chassis Removing To proceed with the removal of the front sprocket, after having loosened the tension of the final drive chain, it is necessary to first remove the left foot- rest support complete with linkages. Then proceed as described: •...
  • Page 306 RS 660 - Tuono 660 Chassis • Remove the spacer (9) from the trans- mission shaft. 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. Installing To proceed with the installation of the front sprock- et, proceed as described:...

  • Page 307: Drive Chain

    RS 660 - Tuono 660 Chassis • Having positioned the fixing screw (4) of the front sprocket, 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 308 RS 660 - Tuono 660 Chassis Removing The transmission chain, although "closed", has a different coloured hammerlock (where provided), which should be used to perform opening / disas- sembling procedures. NOTE WHERE PRESENT, THE HAMMERLOCK (1) MAY ALSO BE IDENTIFIED BY A SIGN (2) APPLIED IN THE MOUNTING LINES DURING MANUFACTURING.
  • Page 309 RS 660 - Tuono 660 Chassis • Remove the inner plate (6). • Collect the inner O-ring rings (7) and completely remove the transmission chain. inspection To check the wear of the drive chain, use the chain checking instrument, P/N: Ognibene - 529510001.
  • Page 310 RS 660 - Tuono 660 Chassis Perform the procedure described as follows to check chain wear: • Tauten the chain. • Place the jaws of the tool on the rollers at the opposite ends of a STRAIGHT length of chain consisting of 8 chain links.
  • Page 311 RS 660 - Tuono 660 Chassis • Check that the links in the transmission chain are not seized and that it can move in both directions. • Use a generic clincher to re-tighten the pins of the link (checking riveting at points "A"). •...
  • Page 312 RS 660 - Tuono 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 250 mm (9.84 in) from the centre of the rear wheel axle (along imaginary line between centres of front...
  • Page 313 RS 660 - Tuono 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 314 RS 660 - Tuono 660 Chassis • Remove the crankcase cover (5). • Undo the lower fixing screw of the rider footrest support to the engine. • Remove the lower fixing screw (5) of the rider footrest support to the engine, complete with washer (6).
  • Page 315 RS 660 - Tuono 660 Chassis • Remove the nut (8). • Remove the washer (9). • Remove the fixing screw (10) of the gear shift lever. • Remove the rider footrest support (11) complete with linkages. CHAS - 315...
  • Page 316 RS 660 - Tuono 660 Chassis • Remove the three fixing screws (12) of the front sprocket cover taking care to recover the bushes. • Remove the front sprocket cover (13). • Remove the two screws (14) and the chain slider fixing caps. •...
  • Page 317 RS 660 - Tuono 660 Chassis • Remove the chain guide (16). • To assemble the chain sliders, carry out the procedures described above in reverse order. Pedaline Rimozione LEFT RIDER FOOTREST • Remove the seeger ring (1). • Extract the pin (2). CHAS - 317...
  • Page 318 RS 660 - Tuono 660 Chassis • Remove the pedal (3) complete with spring (4). • Ensure that the pin (5) cannot rotate and unscrew the nut (6), taking care not to lose the washer (7). • Turn the tie-rod safety retainer (8) and then extract it as indicated in order to remove the lever (9).
  • Page 319 RS 660 - Tuono 660 Chassis • Remove the seeger ring (15) from the peg. • Remove the screw (16) used to fasten the peg. • Extract the peg (17) and if necessary remove the rubber block (18). • To remove the complete rider footrest support, after disconnecting the tie-rod from the gear lever, remove the screw (19) and collect the spring washer (20).
  • Page 320 RS 660 - Tuono 660 Chassis • Remove the nut (21) complete with flat washer (22). • Remove the complete footrest support (23). • If removed, be careful to refit the spacer (24) during the refit phase. RH RIDER FOOTREST •...
  • Page 321 RS 660 - Tuono 660 Chassis • Extract the pin (2). • Remove the pedal (3) complete with spring (4). • Remove the safety O-ring (5) from the pin that blocks the brake pump control rod. • Rotate the pin (6) to release the brake pump control rod and slide it out in or- der to remove it.
  • Page 322 RS 660 - Tuono 660 Chassis • Remove the two rear brake pump fas- tener screws (7). • Remove the cable clamps (8) fastening the wiring of the brake switch to the rear brake pipe. • Operating on the left side of the motor- cycle, remove the screw (9) and collect the spring washer (10).
  • Page 323 RS 660 - Tuono 660 Chassis • Remove the screw (13) and collect the spring washer (14) and the spacer bushing (15). • 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 324 RS 660 - Tuono 660 Chassis • Remove the fixing screw (20) of the brake lever, taking care to collect the washer (21) and the O-rings (22). • Remove the seeger ring (23) from the peg. • Remove the screw (24) used to fasten the peg. •...
  • Page 325 RS 660 - Tuono 660 Chassis • Extract the pin (2). • While pressing the side plates, remove the complete pedal (3). • Check that the plates (4) are aligned correctly before dismantling the pedal, taking care not to lose the spring (5) and the ball (6). •...

  • Page 326: Side Stand

    RS 660 - Tuono 660 Chassis Side stand REMOVAL To remove the side stand, proceed as described: • Unscrew the fixing screw (1) of the gear lever. • Remove then nut (2) from the swing- arm pin and the relative washer (3). •...
  • Page 327 RS 660 - Tuono 660 Chassis • Undo and remove the three sprocket cover fastening screws (7) taking care to recover the "T" bushes (8). • Remove the sprocket cover (9) releas- ing the breather pipe (10). • Remove the screw (11) used to fasten the stand sensor in order to disconnect it from the plate.
  • Page 328 RS 660 - Tuono 660 Chassis • Remove the fastening nut (13) from the centre stand screw taking care to col- lect the washer (14). • Remove the special screw (15) used to fasten the centre stand and then sep- arate it from the plate.
  • Page 329 RS 660 - Tuono 660 Chassis Exhaust Removing the manifold - tail pipe To remove the manifold - exhaust terminal it is necessary to first remove the side fairings, the lower fairings and the radiator. Then proceed as described: • After disconnecting the lambda probes connectors, remove the four nuts from the stud bolts.

  • Page 330: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 331 RS 660 - Tuono 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 with CORNERING is a device to avoid the wheels locking in case of emergency braking also when cornering, thus increasing vehicle stability when braking when compared with a traditional braking system.
  • Page 332 RS 660 - Tuono 660 Braking system The ABS system may be set to three different levels from 1 (minimum slip control) to 3 (maximum slip control), from the specific setting screen (see paragraph in the "SELECTING MAPS"). Level 1 is suitable for performance use by expert riders only. At this level the lifting control of the rear wheel is not active and neither is the cornering system.

  • Page 333: Operating Diagram

    RS 660 - Tuono 660 Braking system THE SAFETY PROVIDED BY THE ABS DOES NOT, IN ANY CASE, JUSTIFY RISKY MANOEU- VRES. EVEN THOUGH THE ABS SYSTEM ENSURES GREATER VEHICLE CONTROL IN THE EVENT OF EMERGENCY BRAKING, ALWAYS OBSERVE THE CORRECT MINIMUM SAFETY DISTANCE FROM THE VEHICLE IN FRONT OF YOU.
  • Page 334 RS 660 - Tuono 660 Braking system ABS functional diagram key 1. Front system circuit 2. Rear system circuit 3. Front brake callipers 4. Rear brake calliper 5. Front brake master cylinder 6. Rear brake pump 7. Front brake control lever 8.

  • Page 335: Abs Operation

    RS 660 - Tuono 660 Braking system Inlets and outlets: 1. Supply to the rear brake calliper. 2. Intake from the rear brake pump. 3. Inlet from front brake master cylinder. 4. Outlet to front brake calliper. ABS OPERATION General specifications: The front circuit is the same as the rear one.
  • Page 336 RS 660 - Tuono 660 Braking system ABS SYSTEM DESCRIPTION The ABS system is a device to avoid wheels locking in case of emergency braking, increasing vehicle braking stability when compared to a traditional braking system. The ABS system improves vehicle control provided that the physical limits of vehicle grip on the road are not exceeded.
  • Page 337 RS 660 - Tuono 660 Braking system • Keeping the screw (1) still, unscrew the locking nut (2) of the rear brake reser- voir (3) disconnecting it from the frame. • Remove the two rear brake pump fas- tener screws (4). •...
  • Page 338 RS 660 - Tuono 660 Braking system • Remove the three plastic cable grom- mets (10) and the rubber cable grom- met (11) to release the brake hose from the ABS sensor wiring. • Remove the two screws (12) fastening the rear brake calliper.
  • Page 339 RS 660 - Tuono 660 Braking system • Disconnect the front brake hoses (17) from the special support. • Remove the two screws (18) fastening the ABS modulator support to the frame. • Turn the ABS modulator slightly to fa- cilitate the disconnection of the con- nector (19).
  • Page 340 RS 660 - Tuono 660 Braking system • Remove the ABS modulator support (21) from the rear. • Working from the left side of the vehi- cle, remove the ABS modulator (22) from the frame. • Unscrew the four fixing screws (23) of the brake pipes and remove the mod- ulator.
  • Page 341 RS 660 - Tuono 660 Braking system • After disconnecting all the rubber and plastic cable grommets that constrain the front brake pipes, remove the fixing screws (24) of the front brake callipers from both sides. • Disconnect the cable grommet (25) from the front mudguard.
  • Page 342 RS 660 - Tuono 660 Braking system MORE OIL IS REQUIRED TO BLEED THE ABS SYSTEM THAN A CONVENTIONAL SYSTEM. FOR THIS REASON, CAREFULLY CHECK THE OIL LEVEL IN THE BRAKE TANK. • If even after bleeding, the front brake lever feels "spongy", the secondary circuit in the ABS control unit must be bled.

  • Page 343: Rear Brake Calliper

    RS 660 - Tuono 660 Braking system • Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard. • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 •...
  • Page 344 RS 660 - Tuono 660 Braking system Removal To remove the rear brake calliper, it is necessary to previously drain the braking system. • Remove the protection cap (1) of the bleed valve and free the wiring harness (2) of the rear ABS sensor. •...
  • Page 345 RS 660 - Tuono 660 Braking system • Remove the two brake calliper fixing screws (6). • Remove the brake calliper (7). Installing To install the rear brake calliper, proceed as de- scribed: • Position the rear brake calliper (1) on the disc.

  • Page 346: Front Brake Calliper

    RS 660 - Tuono 660 Braking system • After having adequately protected the calliper, connect the brake hose, the special screw (3) and tighten it to the prescribed torque. • Fill with oil and bleed the system. • Check the correct functioning of the braking system Front brake calliper Removal NOTE...
  • Page 347 RS 660 - Tuono 660 Braking system • Remove the tube fixing screw (3) and plug the pipe. • Remove the two brake calliper fixing screws (4). • Remove the brake calliper (5). Installing NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH.

  • Page 348: Rear Brake Disc

    RS 660 - Tuono 660 Braking system • Insert and tighten the two brake calliper fixing screws (2) to the prescribed tor- que. • After having adequately protected the calliper, connect the brake hose, the special screw (3) and tighten it to the prescribed torque.

  • Page 349: Disc Inspection

    RS 660 - Tuono 660 Braking system • Remove the phonic wheel (2) • Remove the brake disc (3). 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 350: Front Brake Disc

    RS 660 - Tuono 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 (1) on the rim, making sure it is in the correct direction of installation.
  • Page 351 RS 660 - Tuono 660 Braking system Removal To remove the front brake disc, after removing the wheel, proceed as described: THE FOLLOWING OPERATIONS REFER TO ONE DISC BUT APPLY TO BOTH • Remove the six fixing screws (1) of the tone wheel (if applicable) and of the brake disc on the rim.
  • Page 352 RS 660 - Tuono 660 Braking system of the disc, is less than the minimum value, replace the disc. Disc thickness minimum value: 4 mm (0.16 in) • Using a dial gauge, check that the max- imum oscillation of the disc does not exceed the tolerance;...

  • Page 353: Front Brake Pads

    RS 660 - Tuono 660 Braking system • Insert the six screws (3) and tighten them to the specified torque in the in- dicated order (A-B-C-D-E-F). Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE).
  • Page 354 RS 660 - Tuono 660 Braking system • Remove the spring (3). • Remove the two brake pads (4). Installing THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE). ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS. REPLACING THE PADS OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE STABILITY AND SAFETY, POSING SERIOUS DANGER FOR PEOPLE, OBJECTS AND THE VE- HICLE ITSELF.

  • Page 355: Rear Brake Pads

    RS 660 - Tuono 660 Braking system • Position the spring (2) and insert the locking pin (3). • Tighten the locking pin to the specified torque. • Insert split pin (4) in the pin. • Check the correct operation of the brake system.
  • Page 356 RS 660 - Tuono 660 Braking system • Remove the brake calliper (2). • Remove the stop ring (3). CAUTION BEFORE DISCONNECTING THE PIN (4), CHECK THE PO- SITION OF THE SAFETY SPRING (5); IT MUST BE POSI- TIONED IN THE SAME WAY ON REASSEMBLY. •...
  • Page 357 RS 660 - Tuono 660 Braking system • Remove the pads (6). AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE. Installing To fit the rear brake pads proceed as described: •...
  • Page 358 RS 660 - Tuono 660 Braking system • Insert the stop ring (4). • After having refit the brake calliper and inserting the two fixing screws (5), tighten them to the prescribed torque. • Check the correct functioning of the braking system. Bleeding the braking system PREPARATION OF THE VEHICLE •...
  • Page 359 RS 660 - Tuono 660 Braking system THE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY, BUT ARE VALID FOR BOTH. THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID.
  • Page 360 RS 660 - Tuono 660 Braking system If the brake lever still feels "spongy" after completing all checks, it is necessary to bleed the brakes using this type of procedure. • With the diagnostic tool properly connected, select the function "FRONT BLEEDING" in the section "SETTINGS".

  • Page 361: Front Brake Pump

    RS 660 - Tuono 660 Braking system the brake pedal and it will make it arrive at the end stop. • Close the bleed valve before arriving at the end of the stroke with the pedal. • Repeat the operation until the are no air bubbles in the fluid going into the container.
  • Page 362 RS 660 - Tuono 660 Braking system Removal To remove the front brake pump it is necessary to previously empty the oil from the system. Then proceed as described: • Undo the fastener screw (1) of the oil pipe • Unscrew and remove the two fastening screws (2) of the U-bolt (3) and remove it supporting the brake pump.

  • Page 363: Rear Brake Pump

    RS 660 - Tuono 660 Braking system • Check the condition of the pipe that goes from the reservoir to the brake pump, for cracks or cuts, replace it if damaged. NOTE IF THERE IS ANY DAMAGE TO THE MASTER CYLINDER OR THE PISTON, REPLACE IT.
  • Page 364 RS 660 - Tuono 660 Braking system • Remove the two rear brake pump fas- tener screws (6) at the rider footrest support. • Remove the brake pump (7) complete with reservoir. BRAK SYS - 364...

  • Page 365: Index Of Topics

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 366: Water Pump

    RS 660 - Tuono 660 Cooling system Water pump UBRICATION Pos. Description Type Quantity Torque Notes Oil filter 15 Nm (11.06 lbf ft) Oil filter joint 28.5 Nm (21.02 lbf ft) Oil pressure sensor 13 Nm (9.59 lbf ft) Crankcase cap 20 Nm (14.75 lbf ft) Oil pressure regulation valve 42 Nm (30.98 lbf ft)
  • Page 367 RS 660 - Tuono 660 Cooling system • Remove the water pump cover (2) complete with gasket (3). • Unscrew the rotor (4) and remove it. • Remove the flywheel cover (5) com- plete with gasket (6). • Using a rubber hammer, remove the gear of the water pump (7) complete with washer (8).
  • Page 368 RS 660 - Tuono 660 Cooling system • From the outside of the cover, using a punch remove the sealing ring (9). • Remove the oil seal (10). Installing To proceed with the installation of the water pump, proceed as described: •...
  • Page 369 RS 660 - Tuono 660 Cooling system • Apply a light coat of grease to the slid- ing surface of the oil pump gear (2). • Insert the flat washer (3) on the water pump gear. • Apply a light coat of grease to the sur- face of the flat washer.
  • Page 370 RS 660 - Tuono 660 Cooling system • Insert the gear complete with tool on the cover. • Insert the sealing ring (4). • Insert the second part of the tool (B) and the nut (C). Specific tooling 021037Y Water pump seal insertion tool •...

  • Page 371: Removing The Radiator

    RS 660 - Tuono 660 Cooling system • Insert the impeller (5) and tighten it to the prescribed torque. Removing the radiator To remove the radiator it is necessary to remove the side and lower fairings. Then proceed as de- scribed: •...
  • Page 372 RS 660 - Tuono 660 Cooling system • Operating on the right side of the mo- torcycle, after having released the hose clamp, disconnect the pipe (4) from the radiator. • Empty the filler tank of any coolant left inside. •...
  • Page 373 RS 660 - Tuono 660 Cooling system • Release the hose clamp (8) and dis- connect the pipe (9) from the water pump cover. • Release the hose clamp (10) and dis- connect the pipe (11) from the thermo- static valve fitting. •...

  • Page 374: Removing The Expansion Tank

    RS 660 - Tuono 660 Cooling system • Unscrew the two upper fastening screws (16), taking care to collect the "T"-bushing and support the radiator. • Remove the complete radiator (17) sufficiently to be able to access the electric fan connector (18) and disconnect it.
  • Page 375 RS 660 - Tuono 660 Cooling system • Operating on the left side of the motor- cycle, remove the screw (3) to com- pletely drain the cooling system, taking care to collect the metal washer. • Operating on the right side of the mo- torcycle, after having released the hose clamp, disconnect the pipe (4) from the radiator.

  • Page 376: Notes For Installation

    RS 660 - Tuono 660 Cooling system • Release the expansion tank (6) at the point indicated from the internal fairing and remove it. NOTES FOR INSTALLATION • To refit the expansion tank, first insert the tab (7) on the tank in the appropri- ate slot on the internal fairing and then hook the tank in the centre in the point indicated.
  • Page 377 RS 660 - Tuono 660 Cooling system • Remove the cover (2). • Remove the thermostatic valve (3). Installing To install the thermostatic valve, proceed as de- scribed: • After checking the integrity and effec- tive operation, insert the thermostatic valve (1) in its seat, taking care of its correct positioning.
  • Page 378 RS 660 - Tuono 660 Cooling system • Insert the two screws (3) and tighten them to the specified torque. • Connect the pipe (4) to the fitting and refit the metal clamp (5). • Fill the system with the indicated quantity of coolant and check that there are no leaks in the coupling points of the pipes.
  • Page 379 INDEX OF TOPICS BODYW ODYWORK...
  • Page 380 RS 660 - Tuono 660 Bodywork Seat To remove the saddles, proceed as described: • After inserting the key (1) into the lock located under the tail fairing on the left side of the motorcycle, turn it clockwise and release the passenger seat (2). •...
  • Page 381 RS 660 - Tuono 660 Bodywork • Separate the left support and before removing it completely disconnect the connector (3) of the left arrow. • Remove the clamp (4) that locks the left light switch wiring. • Undo the fastening screw (5) of the an- ti-vibration weight (6) and remove it.
  • Page 382 RS 660 - Tuono 660 Bodywork • Remove the rubber clamps (8) to re- lease the wiring. • Loosen the torx screw (9) fastening the light switch. • Disconnect the two connectors (10) of the light switch. • Slide the light switch (11) off the semi- handlebar to remove it completely.
  • Page 383 RS 660 - Tuono 660 Bodywork Right light switch • Operating on the left side of the motor- cycle, first remove the four fixing screws (1) that join the left support with the right. • Operating on the right hand side of the motorcycle and remove the two screws (2) fastening the right support to the frame.
  • Page 384 RS 660 - Tuono 660 Bodywork • Separate the right support and before removing it completely disconnect the connector (5) of the left arrow. • Undo the fastening screw (6) of the an- ti-vibration weight (7) and remove it. • Unscrew the throttle control locking screw (8).
  • Page 385 RS 660 - Tuono 660 Bodywork • Disconnect the throttle control connec- tor (10). • Remove the throttle control (11) from the semi-handlebar. • Loosen the torx screw (12) fastening the light switch. • Disconnect the right-hand light switch connector (13). BODYW - 385...
  • Page 386 RS 660 - Tuono 660 Bodywork • Slide the light switch (14) off the semi- handlebar to remove it completely. Driving mirrors Depending on the target market, the rear-view mirrors can be equipped with integrated arrows, therefore before proceeding with the removal it is necessary to disconnect the connectors from the fixed con- nectors on the instrument cluster support.

  • Page 387: Instrument Panel

    RS 660 - Tuono 660 Bodywork Instrument panel To remove the instrument panel, first the fairing complete with light assembly must be removed. Then proceed as described: • After unscrewing the two screws (1) fastening the cover (2), remove it •...
  • Page 388 RS 660 - Tuono 660 Bodywork • Remove the washers (6), the spacers (7) the rubber blocks (8) and the wash- ers (9). Headlight assy. To remove the headlight unit, first remove the side fairings, the internal covers, and the internal fair- ings.
  • Page 389 RS 660 - Tuono 660 Bodywork • Remove the rear-view mirrors (4). • Remove the four fastening screws (5) of the headlight unit to the instrument cluster support. • Move aside as required the top fairing complete with light unit to allow to dis- connect the connector (6).

  • Page 390: Headlight Fairing

    RS 660 - Tuono 660 Bodywork • Separate the front fairing (8) from the headlight unit (9). • At the end of the refitting phase, check the correct orientation of the light beams. Headlight fairing • To remove the top fairing, remove the four fixing screws (1) paying attention to collect the washers.
  • Page 391 RS 660 - Tuono 660 Bodywork Disassembling the lock To disassemble the lock it is necessary to first re- move the handle, the internal tail fairing and the left side tail fairing. Then proceed as described: • Unhook the cable (1) from the lock block (2).
  • Page 392 RS 660 - Tuono 660 Bodywork • Remove the lock coupling plate (7) complete with cable. Front wheelhouse REMOVING THE LOWER STEERING YOKE CLOSURE • To remove the lower steering yoke clo- sure, remove the central screw (1) complete with "T" bushing (2). •...
  • Page 393 RS 660 - Tuono 660 Bodywork • Release the rubber cable grommet (6) from the brake hose from the lower steering plate closure. • Remove the lower steering yoke clo- sure (7). Taillight assy. To disassemble the tail light unit it is necessary to first remove the handle, the internal tail fairing and the side tail fairings.

  • Page 394: License Plate Light

    RS 660 - Tuono 660 Bodywork • While supporting the tail light unit, re- move the upper screw (3). • Before proceeding with the removal and releasing the wiring harness, check its correct po- sitioning which must be restored during the refitting phase. •...

  • Page 395: Side Body Panels

    RS 660 - Tuono 660 Bodywork • Remove the two fixing screws (4) and extract the license plate light (5) by re- moving the wiring harness from the li- cense plate holder. Side body panels To disassemble the side panels it is necessary to first remove the saddles.

  • Page 396: Side Fairings

    RS 660 - Tuono 660 Bodywork Side fairings The following operations refer to one side of the vehicle, but are valid for both sides. • To remove the side fairings, start dis- assembly from the inside of the dash- board by removing the three screws (1) fastening the internal cover.
  • Page 397 RS 660 - Tuono 660 Bodywork • Remove the two clips (4). • Remove the screw (5) present under the headlight unit. • Remove the four outer screws (6) from the side fairing. • Remove the complete side fairing (7). BODYW - 397...
  • Page 398 RS 660 - Tuono 660 Bodywork • It is possible to separate the two parts that make up the side fairing by remov- ing the lower screws (8). • Remove the upper screws (9). • Separate the two parts that make up the side fairing.
  • Page 399 RS 660 - Tuono 660 Bodywork • Unhook the expansion tank (3) from point (A) and then from point (B) in or- der to move it away without removing it, taking care not to let the coolant leak out. • Remove the three screws (4) fastening the inner fairing.
  • Page 400 RS 660 - Tuono 660 Bodywork • Keeping the screws on the inside still, unscrew the fixing nuts (2) of the volt- age regulator. • Remove the "T" bushes (3) and collect the screws (4) complete with washers. • Disconnect the connectors (5) from the voltage regulator (6) and remove it.
  • Page 401 RS 660 - Tuono 660 Bodywork • Remove the inner fairing (8). License plate holder To remove the license plate support, proceed as follows: • Disconnect the connector (1) of the rear license plate support wiring har- ness. • Undo the central screw (2). •...

  • Page 402: Rear Mudguard

    RS 660 - Tuono 660 Bodywork • Remove the complete license plate holder (4) by removing the wiring har- ness from the vehicle. During refitting, pay attention to the passage of the wiring harness in the vehicle. Rear mudguard To remove the rear mudguard proceed as follows: •...

  • Page 403: Lower Cowl

    RS 660 - Tuono 660 Bodywork Lower cowl To remove the fairing lug, proceed as described: • Working from both sides of the vehicle, remove the eight fixing screws (1) of the fairing lug. • Before completely removing the fairing lug, disconnect the wiring harness (3) of the side stand sensor from the cable grommets (2).
  • Page 404 RS 660 - Tuono 660 Bodywork • Remove the front cover (2) of the tank. • Unscrew and remove the two front screws (3) and the bushes (4). • Undo and remove the rear screw (5) and the bushing (6). •...
  • Page 405 RS 660 - Tuono 660 Bodywork • Disconnect the fuel pipe (10) from the pump. • Disconnect the fuel pump connector (11). • Remove the fuel tank (12). During refitting, make sure that the screws that secure the fuel pump are tightened correctly. Rear wheelhouse To remove the rear wheel arch, it is necessary to first remove the battery, the fuel tank, the saddles,...
  • Page 406 RS 660 - Tuono 660 Bodywork • Move aside the inertial platform to re- move the two washers below (3). • Disconnect the connector (4) and re- move the inertia platform. • Remove the clamp (5) that binds the main wiring harness to the wheel arch. •...
  • Page 407 RS 660 - Tuono 660 Bodywork • After unscrewing the two screws (8), remove the protective cover (9) of the main relay. • Disconnect the main relay (10) from the holders. • Release the connector (11) from the cable grommet. •...
  • Page 408 RS 660 - Tuono 660 Bodywork • Disconnect the two secondary fuse boxes (13) from the holders. • Unhook the two wiring harnesses (14) from the cable grommet. • Disconnect the connector (15) of the rear ABS sensor. • Unclip the other part of the rear ABS sensor connector from the slide and remove the wiring harness.
  • Page 409 (if applicable) • If the vehicle is equipped with the APRILIA MIA control unit (located on the right side), it is necessary to disconnect the connector and the control unit itself before proceeding with the removal of the wheel arch.

  • Page 410: Front Mudguard

    RS 660 - Tuono 660 Bodywork • Working from both sides, remove the screws (19). • Slide off the wheel arch (20) from the rear to remove it. Front mudguard • To remove the front mudguard, work- ing from both sides of the vehicle, re- move the four screws (1) with corre- sponding washers.
  • Page 411 RS 660 - Tuono 660 Bodywork • Remove the mudguard (3). The following operations refer to a single re- flector but are valid for both • Remove the lock nut (4). • Remove the reflector (5). • Pay attention when refitting, as the pin (A) on the reflector must fit into the hole (B) on the mudguard.
  • Page 412 RS 660 - Tuono 660 Bodywork Rear grab rail • To remove the rear handle, remove the four fixing screws (1). • Remove the rear hand grip (2), taking care to collect the "T" bushes (3) in cor- respondence with the three upper fix- ing points.
  • Page 413 RS 660 - Tuono 660 Bodywork 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 (external / in- ternal) and the instrument panel. Then proceed as described: •...
  • Page 414 RS 660 - Tuono 660 Bodywork • Partially extract the right support to al- low removal of the clamp (5). • Remove the cable grommet (6). • Disconnect the connector (7) for con- necting the right arrow (only for the American market) and then remove the right instrument support.
  • Page 415 RS 660 - Tuono 660 Bodywork • Unscrew and remove the screw (3) from the negative terminal (-). • Move the negative lead (4) aside. • Unscrew and remove the screw (5) of the positive terminal (+). • Move the positive lead (6) aside. TAKE UTMOST CAR AND DO NOT MAKE CONTACT BE- TWEEN THE BATTERY TERMINALS AND ANY METALLIC OBJECT IN ORDER TO PREVENT THE RISK OF SHORT...
  • Page 416 RS 660 - Tuono 660 Bodywork • Remove the two top screws (2). • Remove the left tail fairing (3). • Operating from the right side of the ve- hicle, remove the three side screws (4). • Remove the two top screws (5). BODYW - 416...
  • Page 417 RS 660 - Tuono 660 Bodywork • Remove the right tail fairing (6). • Remove the central tail fairing (7). Copertura terminale To disassemble the terminal covers, proceed as described: LEFT TERMINAL COVER • Remove the front fixing screw (1) pay- ing attention to collect the washer and the bushing.

  • Page 418: Terminal Cover

    RS 660 - Tuono 660 Bodywork RIGHT TERMINAL COVER To remove the right side terminal cover it is nec- essary to partially extract the right side rider foot- peg support as described: • Remove the nut (3) with its washer. •...
  • Page 419 ABS: 331 Air filter: 61, 64 Battery: 414 Brake: 343, 346, 348, 350, 353, 355, 361, 363 Brake calliper: 343, 346 Brake disc: 348, 350 Brake pads: 353, 355 Brake pump: 361, 363 Bushings: Chain: 19, 208, 210, 211, 307, 313 Chain tensioner: 208, 211 Clutch: 84, 163, 168, 169, 171, 175–177, 181 Connecting rods: 188, 191...
  • Page 420 Keys: 119 License plate holder: 401 Maintenance: 14, 55 Mirrors: 386 Mudguard: 402, 410 Oil filter: 61 Oil sump: 230, 231 Pistons: 187, 191 Primary shaft: 131, 138 Radiator: 371 Rear wheel: 282 Recommended products: 56 Scheduled maintenance: 55 Secondary shaft: 133, 139 Shock absorber: Shock absorbers: 267 Side fairings: 396...

This manual is also suitable for:

Rs 660 2021Rs 660

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