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APRILIA RS 660, Service Station Manual, Page: 239 / 420

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APRILIA RS 660 Service Station Manual Download Page 239

•

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.

•

To fit the semi-handlebar, repeat the procedures previously described in reverse order and

finally tighten the six semi-handlebar screws to the specified torque.

RS 660 - Tuono 660

Suspensions

SUSP - 239

Summary of Contents for RS 660

Page 1: ...SERVICE STATION MANUAL 2Q000453 RS 660 Tuono 660 ...

Page 2: ...le itself All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only While the basic features as described and illustrated in this manual remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication before...

Page 3: ...s and changes in repair procedures are communicated to all Aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates a...

Page 4: ......

Page 5: ...LIVERY PRE DE CHARACTERISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS BODYWORK BODYW ...

Page 6: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 7: ... brake light push button Turn indicators and their warning lights Instrument cluster Instrument cluster warning lights Horn Electric starter Engine stop via emergency stop switch and side stand Through the diagnostic tool check that the last mapping version is present in the control unit s and if required program the control unit s again consult the technical service website to know about avail ab...

Page 8: ...GE Always use a specific charger for lithium batteries to recharge the battery To avoid damage to the battery the charging voltage must NEVER be higher than 15 volts Do not charge the battery with a charger with automatic DESULPHATION MODE using a voltage higher than 15 volts Always remove the battery from the vehicle before connecting it to the charger Stop charging if the battery feels warm to t...

Page 9: ...inals Do not use the battery in combination with primary batteries such as dry batteries or batteries of different capacity type and brand Do not use the battery if it emits a strange odour emits heat changes colour or deforms or if it presents any anomaly Stop use immediately if the battery is in use or under charge THE BATTERY DOES NOT CONTAIN HARMFUL POLLUTANTS CORROSIVE ACIDS OR TOXIC HEAVY ME...

Page 10: ...sing the six cells This operation is extremely important in or der to have the best battery perform ance over time Recharge the battery following the specifications indicated on the battery see photo and using a suitable bat tery charger NOTE IN THE SHOWN EXAMPLE IT IS IMPORTANT TO USE A BATTERY CHARGER WITH 1 2 AMPERE CHARGING TIME 5 10 HOURS OR 5 AMPERE CHARGING TIME 1 HOUR Levels check Hydrauli...

Page 11: ...rect operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Check the frame and engine numbers Check included tools where applicable Licence plate fitting Locks checking Tyre pressure check Fitting of mirrors and possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY BURST CAUTION CHECK AND ADJUST TYRE PRESSUR...

Page 12: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 13: ... ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot parts The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down Coolant Th...

Page 14: ...F CHILDREN Battery electrolyte and hydrogen gas WHERE REQUIRED CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARL...

Page 15: ...ble material Lubricate the parts when possible before reassembling them When tightening screws and nuts begin with the larger diameter or internal ones proceeding diagonally Tighten with subsequent steps before applying the prescribed torque Always replace the locknuts gaskets seal rings snap rings O Rings OR cotter pins and screws if they have damaged thread with new ones When disassembling the b...

Page 16: ...OCKING A WHEEL OR CAUSING OTHER PROBLEMS THAT WOULD COMPROMISE MA NOEUVRABILITY LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your riding speed during the running in period Th...

Page 17: ...HE WARRANTY This number consists of numbers and letters as in the example shown below ZD4KSA000YSXXXXXX KEY ZD4 WMI World Manufacturer Identifier code KS model A00 Europe UA0 USA 0 digit free Y year of manufacture S production plant S Scorzè XXXXXX serial number 6 digits CHASSIS NUMBER The chassis number is stamped on the RH side of the headstock Chassis No ENGINE NUMBER The engine number is stamp...

Page 18: ...t camshafts bucket tappets and valve clearance adjustment with calibrated pads Lubrication system Wet sump with heat exchanger coaxial with oil filter Oil pump Trochoidal pump Oil filter With external cartridge filter Cooling Liquid Cooling system 3 way thermostatic valve cooling radiator with electric fan and expansion tank Coolant pump Centrifugal bearingless aspirating pump with integrated alum...

Page 19: ...e Regina 110 links With sealed master link Model 520 135 ZRA Electrical system ELECTRICAL SYSTEM Specification Desc Quantity Spark plugs NGK IR MR9DI 7 Electrode gap 0 7 0 8 mm 0 027 0 031 in Battery BS BATTERY BSLi 04 LITHIUM 12V 48Wh 280A Alternative solution YUASA YTZ10S 12V 8 6 Ah Coils Stick coil Recharging system Flywheel with rare earth magnets Alternator 360 W Main fuses 30A Secondary fuse...

Page 20: ...easurements refer to the bare chassis Angle C 24 1 measurements with respect to bare chassis Brakes BRAKES Specification Desc Quantity Front 320 mm 12 60 in discs four piston callipers with 32 mm 1 26 in pistons and 2 pads radial master cylinder and steel braided brake hose Rear 220 mm 8 66 in disc two piston calliper with 34 mm 1 34 in pistons master cylinder with integrated reservoir and steel b...

Page 21: ...E REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED BEFORE FITTING THE NEW SCREWS CLEAN THE THREADED HOLES CAREFULLY MAKING SURE THAT ALL TRACES OF THE OLD THREAD LOCK SEALANT HAVE BEEN ELIMINATED Chassis Front side FAIRING FRONT Pos Description Type Quantity Torque Notes 1 Flanged nut fastening rear view mir ror M6 4 4 Nm 2 95 lb ft 2 Top fairing fastener TBEI screw M4 4 0 5 Nm 0 36 lbf ft R...

Page 22: ...Torque Notes 1 Wheel axle M16 1 65 Nm 47 94 lb ft 2 Front brake disc flanged hex fixing screw M8x20 12 25 Nm 18 43 lb ft FRONT FORK Pos Description Type Quantity Torque Notes 1 Cap 2 22 5 Nm 16 60 lbf ft Characteristics RS 660 Tuono 660 CHAR 22 ...

Page 23: ...ng screw 2 22 5 Nm 16 60 lbf ft 4 Wheel pin safety locking screw M8 1 18 Nm 13 27 lbf ft 5 ABS sensor screw M5 1 6 Nm 4 42 lb ft FRONT BRAKE CALLIPER Pos Description Type Quantity Torque Notes 1 TCC screw fastening brake calliper M10x55 4 50 Nm 36 87 lb ft RS 660 Tuono 660 Characteristics CHAR 23 ...

Page 24: ...t 1 40 5 Nm 29 50 3 68 lb ft Tightening 6 Steering yoke lower closure central hex fixing screw 1 Nm lb ft 7 Steering yoke lower closure side fix ing TBEI screw M6x30 2 Nm lb ft 8 Self locking nuts fastening steering end of the stroke pins M8 2 25 Nm 18 43 lb ft HANDLEBAR CONTROLS Pos Description Type Quantity Torque Notes 1 Domed head torx screw fastening semi handlebar M10x55 2 46 Nm 33 92 lbf ft...

Page 25: ...Torque Notes 1 Clutch control fastener screw M6 1 10 Nm 7 37 lb ft FRONT BRAKE MASTER CYLINDER Pos Description Type Quantity Torque Notes 1 Screw fastening front brake master cylinder M6 2 10 Nm 7 37 lb ft RS 660 Tuono 660 Characteristics CHAR 25 ...

Page 26: ...INSTRUMENTS Pos Description Type Quantity Torque Notes 1 TCCIC screw fastening instrument cluster support to chassis M6x20 4 6 5 Nm 4 79 lb ft Central part Characteristics RS 660 Tuono 660 CHAR 26 ...

Page 27: ...ing frame M10 1 50 Nm 36 87 lb ft 3 Hex screw fixing engine bracket to chassis M8x20 4 25 Nm 18 43 lb ft 4 Hex screw fixing engine bracket to chassis M10 4 50 Nm 36 87 lb ft 5 Nut fixing engine pin to chassis M12 1 50 Nm 36 87 lb ft SIDE FAIRINGS Pos Description Type Quantity Torque Notes 1 Screw fixing inner fairing to radiator M5 4 18 Nm 13 27 lbf ft RS 660 Tuono 660 Characteristics CHAR 27 ...

Page 28: ...Torque Notes 1 Front mudguard fixing screw M5 4 3 Nm 2 21 lbf ft TANK Pos Description Type Quantity Torque Notes 1 Tank breather couplings M7 2 3 Nm 2 21 lbf ft 2 Flanged screw fastening fuel pump M5x15 6 4 Nm 2 95 lb ft Characteristics RS 660 Tuono 660 CHAR 28 ...

Page 29: ...otes 1 Screws fastening cap and tray M5 7 4 Nm 2 95 lb ft 2 Ignition switch assembly fixing shear head screw M8x40 1 Bring to break 3 SHC screw fastening ignition switch assembly M8x40 1 20 Nm 14 75 lbf ft RS 660 Tuono 660 Characteristics CHAR 29 ...

Page 30: ... Nm 0 73 0 88 lb ft 3 SWP TCB flanged screw fastening bleed valve bracket M5x20 1 1 1 2 Nm 0 73 0 88 lb ft 4 Special TBEI screw fastening the base of the filter box to the canister bracket M5x25 1 1 1 2 Nm 0 73 0 88 lb ft THROTTLE BODY Pos Description Type Quantity Torque Notes 1 Self tapping TCB screw fixing air pressure sensor 1 1 1 2 Nm 0 73 0 88 lb ft Characteristics RS 660 Tuono 660 CHAR 30 ...

Page 31: ...1 Screw fixing radiator to support M6 2 6 Nm 4 42 lb ft 2 Screw fixing the electric fan to the ra diator M6 3 7 5 Nm 5 53 lb ft SILENCER Pos Description Type Quantity Torque Notes 1 Lambda probe M12 2 25 Nm 18 43 lb ft RS 660 Tuono 660 Characteristics CHAR 31 ...

Page 32: ...stening nuts M7 4 13 Nm 9 58 lbf ft FOOTRESTS Pos Description Type Quantity Torque Notes 1 TE flanged screws fixing footpegs to the crankcase M10 2 45 Nm 33 19 lb ft 2 SHC screws fixing passenger foot pegs M8x45 4 25 Nm 18 43 lb ft Characteristics RS 660 Tuono 660 CHAR 32 ...

Page 33: ... tie rod to gear lever M6 1 8 5 Nm 6 26 lbf ft Loct 243 REAR BRAKE PUMP Pos Description Type Quantity Torque Notes 1 Rear brake lever fixing pin M8 1 25 Nm 18 43 lb ft With thread lockers 2 TE flanged screws fastening rear brake master cylinder M6x16 2 8 Nm 5 90 lb ft With thread lockers RS 660 Tuono 660 Characteristics CHAR 33 ...

Page 34: ...es 1 Pin fixing side stand to support 1 12 Nm 8 85 lbf ft Loct 243 2 Nut fixing stand pin to bracket M10 1 30 Nm 22 12 lb ft Loct 243 3 Screws fixing the stand to the engine crankcase M10 2 45 Nm 33 19 lb ft Characteristics RS 660 Tuono 660 CHAR 34 ...

Page 35: ...anged hex screw for horn fixing M8 1 15 Nm 11 06 lbf ft Starter relay cables fastening screws M5 2 4 Nm 2 95 lb ft Screw fastening ground cable to the engine M6 2 10 Nm 7 37 lb ft CENTRAL ELECTRICAL SYSTEM Pos Description Type Quantity Torque Notes 1 Inertial platform TEFL fixing screws M6x25 2 7 5 Nm 5 53 lb ft RS 660 Tuono 660 Characteristics CHAR 35 ...

Page 36: ...Back side REAR BODYWORK Pos Description Type Quantity Torque Notes 1 Handle fixing screws M8 4 18 Nm 13 27 lbf ft Characteristics RS 660 Tuono 660 CHAR 36 ...

Page 37: ...ening rear brake disc M8x20 5 25 Nm 18 43 lb ft 3 Rear wheel axle nut M20 1 120 Nm 88 50 lbf ft SWINGARM Pos Description Type Quantity Torque Notes 1 Swingarm pivot bolt self locking nut M16 1 110 Nm 4 33 lbf ft 2 Chain feeder shoe SHC flanged fas tening screws M5x16 2 2 Nm 1 47 lb ft RS 660 Tuono 660 Characteristics CHAR 37 ...

Page 38: ...ed self locking shock absorber fastening nuts M10 2 50 Nm 36 87 lb ft REAR BRAKE CALLIPER Pos Description Type Quantity Torque Notes 1 TE flanged screws fastening rear brake calliper M8 2 25 Nm 18 43 lb ft With thread lockers Characteristics RS 660 Tuono 660 CHAR 38 ...

Page 39: ...9 22 5 27 5 Nm 16 60 20 28 lb ft Lubricate with oil 4 Crankcase halves mating screws M6x70 1 10 8 13 2 Nm 7 97 9 74 lb ft 5 Crankcase halves mating flanged hex screws M6x40 3 10 8 13 2 Nm 7 97 9 74 lb ft 6 Crankcase halves mating flanged hex screws M8x60 4 22 5 27 5 Nm 16 60 20 28 lb ft Lubricate with oil 7 Crankcase halves mating threaded hex screws M6x30 4 10 8 13 2 Nm 7 97 9 74 lb ft 8 Pistons ...

Page 40: ...2 12 Nm 8 85 lbf ft 2 Head cover fastening screws 4 10 Nm 7 38 lbf ft 3 TE flanged coil fixing screw M6x16 2 12 Nm 8 85 lbf ft HEAD VALVES Pos Description Type Quantity Torque Notes 1 Cam tower fixing screws 12 11 Nm 8 11 lbf ft Characteristics RS 660 Tuono 660 CHAR 40 ...

Page 41: ...nut fixing cylinder head M10 6 30 Nm 22 12 lb ft Pre tightening lu bricate with MOLY KOTE G RAPID PLUS 6 Flanged nut fixing cylinder head M10 6 180 Tightening TIMING SYSTEM Pos Description Type Quantity Torque Notes 1 Timing gears Torx button head fixing screws 4 30 Nm 22 13 lbf ft 2 Chain tensioner slider support screw M8 1 18 5 Nm 13 64 lbf ft Pre permeated 3 Cap 1 20 Nm 14 75 lbf ft 4 Special s...

Page 42: ...CRANKSHAFT Pos Description Type Quantity Torque Notes 1 Connecting rod screws M 4 1 15 Nm 11 06 lbf ft 2 20 Nm 110 14 75 lbf ft 110 Lubricate with Pankl oil Characteristics RS 660 Tuono 660 CHAR 42 ...

Page 43: ...ar selector drum fixing flanged hex screw 1 25 Nm 18 44 lbf ft 3 Gear sensor fixing round headed screws 2 6 Nm 4 43 lbf ft 4 Special screw 1 12 Nm 8 85 lbf ft GEARBOX COMPONENTS Pos Description Type Quantity Torque Notes 1 Flanged hex head screw used for fastening the pinion M10x25 1 50 Nm 36 87 lb ft With thread lockers RS 660 Tuono 660 Characteristics CHAR 43 ...

Page 44: ...nsor 1 13 Nm 9 59 lbf ft 4 Crankcase cap 1 20 Nm 14 75 lbf ft 5 Oil pressure regulation valve 1 42 Nm 30 98 lbf ft 6 Drainage plug 1 20 Nm 14 75 lbf ft 7 Sump fixing flanged hex screw M6 10 12 Nm 8 85 lbf ft 8 Oil pump fastening screws M5 2 6 Nm 4 43 lbf ft 9 Oil pump gear fastener screw 1 12 Nm 8 85 lbf ft Characteristics RS 660 Tuono 660 CHAR 44 ...

Page 45: ...p cover fixing screws M6 5 12 Nm 8 85 lbf ft 2 Water pump impeller 1 4 5 Nm 3 32 lbf ft CLUTCH Pos Description Type Quantity Torque Notes 1 Clutch fastening nut 1 175 Nm 129 07 lbf ft 2 Screws for springs M6 3 10 Nm 7 37 lb ft RS 660 Tuono 660 Characteristics CHAR 45 ...

Page 46: ...s Description Type Quantity Torque Notes 1 Clutch control lever flanged hex fix ing screw M6x20 1 10 Nm 7 38 lbf ft 2 Clutch cover flanged hex fixing screw 8 12 Nm 8 85 lbf ft Characteristics RS 660 Tuono 660 CHAR 46 ...

Page 47: ... screws M6x35 2 12 Nm 8 85 lbf ft 2 Starter ring gear containment plate fastening screw M6x35 1 12 Nm 8 85 lbf ft 3 Rotor fastening screw M14x30 1 195 Nm 143 82 lbf ft 4 Stator SHC fixing screws M6x30 3 10 Nm 7 38 lbf ft Pre impregnated 5 Free wheel on rotor SHC fixing screws M6x18 3 14 Nm 10 33 lbf ft Pre impregnated 6 Stator wiring harness support plate fixing screws M5x14 2 3 Nm 2 21 lbf ft Pre...

Page 48: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 49: ...r 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 RS 660 Tuono 660 Special tools S TOOLS 49 ...

Page 50: ...ng 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 Special tools RS 660 Tuono 660 S TOOLS 50 ...

Page 51: ...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 Flywheel extractor RS 660 Tuono 660 Special tools S TOOLS 51 ...

Page 52: ... 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 Special tools RS 660 Tuono 660 S TOOLS 52 ...

Page 53: ...Stores code Description 020888S Pre load tube clamp 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles RS 660 Tuono 660 Special tools S TOOLS 53 ...

Page 54: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 55: ...ket rear sprocket Chain slider I I I I Steering bearings and steering play I I I I I I I Wheel bearings Wheels I I I I I I I Diagnosis by tool I I I I I I I Brake discs Brake pads wear 1 I I I I I I I Air filter I R I R Engine oil filter R R R R R R R Raked I I I I Vehicle general operation I I I I I I I Valve clearance A A Cooling system I I I I Brake systems I I I I I I I Safety switches stand s...

Page 56: ...I I I I I Safety switches stand stop clutch extra negative stroke gas control I I I I I Brake Fluid I I I I I Coolant I I I I I Fork oil 3 R Engine oil R R R R R Headlight aiming I I I I Fork oil seals I I Tyres pressure wear 1 I I I I I Nut bolt tightness I I I I I Labour time minutes 90 110 190 110 280 NOTE AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRO...

Page 57: ...NC 956 16 DOT 4 brake fluid Synthetic brake fluid SAE J 1703 FMVSS 116 ISO 4925 CU NA NC 956 DOT4 Fork oil 7 5W Fork oil SAE 7 5W Spark plug To remove the spark plugs the fuel tank and the complete filter box must first be removed Then proceed as described After releasing the coil connectors from the supports disconnect them Disconnect the corrugated pipe from the cable glands and unscrew the scre...

Page 58: ... CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km 10 miles IN EXTRA URBAN CONDITIONS ENOUGH TO WARM UP THE ENGINE OIL TO OPERATING TEMPERATURE Shut off the engine and wait a few sec onds Keep the vehicle upright with both wheel...

Page 59: ...THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MARKING OR EXCEED THE MAXIMUM MARKING AN OIL LEVEL NOT WITHIN THE MINIMUM AND MAXIMUM MARKINGS MAY CAUSE SEVERE ENGINE DAMAGE Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY Place a container with suitable capaci ty under the drainage plug Unscrew and remove the drainage plug Unscrew and remove the filler cap RS ...

Page 60: ...capacity with engine oil before fit ting Screw and tighten the drainage plug Add 2700 cc 164 76 cu in of new en gine oil of the specified type Screw on the filler cap Warm up the engine up by running it for a few minutes then switch it off After thirty seconds check the level with a oil level dipstick Top up if necessary CAUTION THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MARKING OR EXCEED TH...

Page 61: ...ER Spread a thin layer of oil on the sealing ring of the new engine oil filter Insert and screw the new engine oil filter in the seat filling the filter to 1 3 of its capacity with engine oil before fitting See also Replacement Air filter Remove the fuel tank Disconnect the intake air temperature sensor connector Remove the eleven filter box lid fastening screws RS 660 Tuono 660 Maintenance MAIN 6...

Page 62: ... 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 Having removed the canister using pli ers remove the metal clamp 1 and disconnect the vacuum valve 2 Maintenance RS 660 Tuono 660 MAIN 62 ...

Page 63: ...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 connect it RS 660 Tuono 660 Maintenance MAIN 63 ...

Page 64: ...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 Remove the eleven fixing screws 2 of the filter box cover Maintenance RS 660 Tuono 660 MAIN 64 ...

Page 65: ... 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 RS 660 Tuono 660 Maintenance MAIN 65 ...

Page 66: ...the main wiring harness Remove the two fixing screws 8 of the ECU support to the filter housing Remove the fixing screw 9 and rela tive bush 10 of the sensor 11 After removing the two springs 12 from the breather pipes 13 discon nect them Maintenance RS 660 Tuono 660 MAIN 66 ...

Page 67: ...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 Disconnect the two connectors 17 of the ignition switch assembly from the filter box RS 660 Tuono 660 Maintenance MAIN 67 ...

Page 68: ... complete filter box the throttle body the canister the ignition switch assembly and clutch housing Then proceed as described COMPONENTS DISASSEMBLY Working from the left side of the mo torcycle having removed the inspec tion cap rotate the engine clockwise until the top dead centre of cylinder 1 is reached Rotate a further 20 to intercept the hole in the crankcase on the right side of the vehicle...

Page 69: ...haft timing pin 2 pieces Using the special tools and a T40 torx insert loosen the two fixing screws 4 of the intake camshaft timing gear Specific tooling 669N 5 BETA Ratchet torque wrench rectan gular attachment 736 10 10 1 STAHLWILLE Insert holder for torque wrench with rectangular attachment Complete the removal by working from the outside using a ball end torx wrench Working on the chain tensio...

Page 70: ...e 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 Remove the third pin 3 Maintenance RS 660 Tuono 660 MAIN 70 ...

Page 71: ...ific tool 5 on the ex ternal cam of the intake shaft as shown and rotate the intake camshaft forward to free the valves Specific tooling 021044Y Intake camshaft disarming lever Remove the second pin 2 Completely unscrew the ten fixing screws 6 of the cam tower RS 660 Tuono 660 Maintenance MAIN 71 ...

Page 72: ... needs ad justment remove the intake camshaft 8 or the exhaust camshaft Remove the bucket tappet 9 of the valve requiring adjustment Remove the calibrated pad 10 and replace it with the one needed to obtain the correct valve clearance Maintenance RS 660 Tuono 660 MAIN 72 ...

Page 73: ...afts them selves position them on the head The exhaust camshaft has two grooves in the indicated point lubricate with MOLYKOTE G RAPID PLUS The correct positioning is determined by the holes for the insertion of the pins facing up wards Position the cam tower 7 complete with fixing screws with the exception of the two that will subsequently fix the upper slider RS 660 Tuono 660 Maintenance MAIN 73...

Page 74: ...Camshaft timing pin 2 pieces Position the timing gear 4 complete with chain on the intake camshaft Position the specific tool 5 on the ex ternal cam of the intake camshaft as shown and rotate the intake camshaft to intercept the insertion point of the third pin 3 on the cam tower Specific tooling 021044Y Intake camshaft disarming lever 021043Y Camshaft timing pin 2 pieces Maintenance RS 660 Tuono ...

Page 75: ...respect to the slotted holes of the gears them selves Insert and hand tighten one screw of the timing gear Position the plate 11 complete with sliding block and relative screws 10 Tighten the two screws to the prescri bed torque After verifying correct operation use a rubber hammer to arm the chain ten sioner RS 660 Tuono 660 Maintenance MAIN 75 ...

Page 76: ...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 Insert the plug 5 complete with a new copper washer 6 and tighten it to the prescribed torque Maintenance RS 660 Tuono 660 MAIN 76 ...

Page 77: ... remove the fuel tank the side fairings the complete filter box the throttle body and the canister Then proceed as described Working from the left side of the mo torcycle having removed the inspec tion cap rotate the engine clockwise until the valve to be measured is freed Using a feeler gauge measure the dis tance between the cam of the camshaft and the valve bucket tappet Characteristic Intake v...

Page 78: ...PWARDS 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 1 90 mm 0 0748 in 1 92 mm 0 0756 in 1 95 mm 0 0768 in 1 97 mm 0 0775 in 2 mm 0 0787 in 2 02 mm 0 0795 in Maintenance RS 660 Tuono 660 MAIN 78 ...

Page 79: ... 0 0945 in 2 42 mm 0 0953 in 2 45 mm 0 0964 in 2 47 mm 0 0972 in 2 50 mm 0 0984 in 2 52 mm 0 0992 in 2 55 mm 0 1004 in 2 57 mm 0 1012 in 2 6 mm 0 1024 in 2 62 mm 0 1031 in 2 65 mm 0 1043 in 2 67 mm 0 1051 in 2 7 mm 0 1063 in 2 72 mm 0 1071 in 2 75 mm 0 1083 in 2 77 mm 0 1090 in 2 8 mm 0 1102 in 2 82 mm 0 1110 in 2 85 mm 0 1122 in 2 87 mm 0 1129 in 2 9 mm 0 1142 in 2 92 mm 0 1150 in 2 95 mm 0 1161 ...

Page 80: ...urface Looking from the left side of the vehicle through the specific opening on the in ternal right fairing ensure that the liq uid level in the expansion tank is between the FULL maximum and LOW minimum marks WARNING CARRY OUT THE CHECK AND TOP UP THE REFRIGER ANT LIQUID WITH THE ENGINE SWITCHED OFF AN COLD Top up From the right hand side of the motor cycle remove the fastener screw 1 of the ins...

Page 81: ...d level in the res ervoir is above the MIN reference mark MIN minimum level MAX maximum level If the fluid does not reach at least the MIN refer ence mark Check brake pads and discs for wear If the pads and or the disc do not need replacing top up the fluid If the pads and or the disc have to be replaced check the brake fluid and top up if necessary Top up RISK OF BRAKE FLUID SPILLING DO NOT OPERA...

Page 82: ...ORCYCLE IN THE VICINITY OF THE RES ERVOIR WITH ABSORBENT MATERIAL Recommended products DOT 4 brake fluid Synthetic brake fluid SAE J 1703 FMVSS 116 ISO 4925 CUNA NC 956 DOT4 Front braking system Use a short cross head screwdriver to undo the screws 1 of the front braking system fluid reservoir 2 Lift and remove the cover 3 complete with screws 1 and the gasket 4 Top up the reservoir 2 with recom m...

Page 83: ...NG NEW BRAKE PADS DO NOT FILL TO THE MAX LEVEL WITH WORN PADS AS THIS WILL CAUSE FLUID TO ESCAPE WHEN REPLACING BRAKE PADS CHECK BRAKING EFFICIENCY IF THE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE LEVER IS TOO LONG OR IN CASE OF FLUID LOSS IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM Adjusting the levers FRONT BRAKE LEVER It is possible to adjust the distance between the end of the lever...

Page 84: ...S IN THE WORKSHOP BOOKLET AVAILA BLE ALSO AT ANY Official Aprilia Dealer Clutch system Regolazione leva frizione Adjust the clutch when the engine stops or the ve hicle tends to move forward even when clutch lever is operated and the gear engaged or if the clutch slides resulting in acceleration delay con sidering the engine revs Minor adjustments can be realized by acting on the clutch lever adju...

Page 85: ...es not stop or that the vehicle does not tend to move or that the clutch does not slip during acceleration or while rid ing Headlight adjustment NOTE IN COMPLIANCE WITH LOCAL LEGISLATION SPECIFIC PROCEDURES MUST BE FOLLOWED WHEN ALIGNING THE LIGHTS To quickly check if the headlamp is aimed correct ly place the vehicle on a level surface 10 m 32 8 ft from a vertical wall Turn on the low beam light ...

Page 86: ...ht beam NOTE CHECK THAT THE VERTICAL ALIGNMENT OF THE BEAM IS CORRECT HIGH BEAM HEADLIGHT Operating from underneath the head lamp unit turn the adjuster screw 3 TIGHTEN clockwise to lower the light beam LOOSEN anticlockwise to raise the beam This adjuster screw may be used to adjust the vertical alignment of the high beam headlight beam NOTE CHECK THAT THE VERTICAL ALIGNMENT OF THE BEAM IS CORRECT...

Page 87: ... as described Disconnect the connectors 1 of the coils from the canister support Disconnect the corrugated pipe 2 from the two cable glands 3 on the canister support Remove the fixing screw 4 and free the earth cable 5 taking care to re cover the bush below Extract the complete canister 6 RS 660 Tuono 660 Maintenance MAIN 87 ...

Page 88: ...port If the vacuum valve 10 needs to be replaced after removing the metal clamps 11 and disconnecting the pipes 12 disconnect the connector 13 and proceed with the replace ment If it is necessary to replace the safety valve 14 after removing the clips 15 and disconnecting the pipes 16 pro ceed with the replacement Maintenance RS 660 Tuono 660 MAIN 88 ...

Page 89: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 90: ...g harness 1 x Engine Battery Earth Cable 8 x Edge clip Sheet Ø10mm 1 x Edge clip Sheet Ø20mm 2 Connector supports AMP 1 x ABS sensor support 1 x Horn cables grommet 1 x Instrument Cluster cable grommets clamp Engine side 1 x Engine cable harness 4 x Edge clip Sheet Ø10mm 2 x Edge clip Sheet Ø20mm 1 x Tyco connector support Small parts and mountings Vehicle side 3 x Small black 160x2 5 clamps Engin...

Page 91: ...eel Regulator connection Lambda connection check 1 and 2 Check that lambda probe cable 1 and 2 is correctly connected Check that the ABS connector is correctly inserted Check that the ABS sensors are correctly connected Front and Rear Check the fan connector connection Check the starter relay connection with the main wiring harness Check that the cables on the starter relay are connected correctly...

Page 92: ...ECTORS CONNECTED CORRECTLY TO ENSURE THAT THE VEHICLE FUNCTIONS CORRECTLY THE INSTRUCTIONS FOR ROUT ING AND FASTENING THE WIRING HARNESS THROUGHOUT THE VEHICLE MUST BE FOL LOWED PRECISELY TO ENSURE THAT THE VEHICLE FUNCTIONS CORRECTLY AND RELIABLY Front side TABLE A PRE ASSEMBLY OF THE EXTER NAL AIR TEMPERATURE SENSOR Using a small clamp 1 fasten the ex ternal air temperature sensor 2 to the right...

Page 93: ... to the right fork end pass the wiring 2 inside and lock it with a clamp 3 in the indicated point TABLE B1 FRONT ABS SENSOR Fasten the wiring of the front ABS sen sor to the brake pipe using 3 cable clamps 4 RS 660 Tuono 660 Electrical system ELE SYS 93 ...

Page 94: ...LEBAR ZONE The wiring of the throttle control 1 and of the right light switch 2 must be in serted inside the instrument support passing through the point indicated TABLE D LEFT HANDLEBAR ZONE The wiring of the clutch switch 1 and of the left light switch 2 must be in serted inside the instrument support passing through the point indicated Electrical system RS 660 Tuono 660 ELE SYS 94 ...

Page 95: ... with a clamp 1 on the support located inside the instrument cluster support and with an additional clamp 2 in the indicated point TABLE E1 INSTRUMENT CLUSTER SUP PORT ZONE Place the wiring in the clip 3 NOTE THE CLIP IS OPTIONAL RS 660 Tuono 660 Electrical system ELE SYS 95 ...

Page 96: ... support and pass the wiring through the cable grommet 2 as shown TABLE B PRE ASSEMBLY OF VOLTAGE REGULATOR ON THE LEFT INNER SIDE Fix the voltage regulator 1 using the two screws with the relative bolts and insert a clamp 2 in the indicated point Electrical system RS 660 Tuono 660 ELE SYS 96 ...

Page 97: ... cable grommet clip 2 TABLE D ELECTRIC FAN PRE ASSEMBLY Fix the electric fan to the radiator and lock the wiring using a clamp 1 in the indicated point TABLE E MAIN WIRING HARNESS Pass the main wiring as shown TABLE E1 MAIN WIRING HARNESS Pass the main wiring as shown RS 660 Tuono 660 Electrical system ELE SYS 97 ...

Page 98: ...TABLE E2 MAIN WIRING HARNESS Pass the main wiring as shown TABLE E3 MAIN WIRING HARNESS Pass the main wiring as shown Electrical system RS 660 Tuono 660 ELE SYS 98 ...

Page 99: ... FLYWHEEL Pass the wiring 4 of the voltage reg ulator behind the radiator pipe Connect the connectors 5 6 to the voltage regulator 7 and lock the wir ing using a clamp 8 TABLE G HORN AND STAND SENSOR The horn wiring 1 must pass behind the radiator pipe and fastened to the cable grommet 2 RS 660 Tuono 660 Electrical system ELE SYS 99 ...

Page 100: ...airing TABLE H ELECTRIC FAN Fasten the main wiring to the cable grommet 1 located on the radiator support and connect the connector 2 to the clip as indicated Secure the wiring of the electric fan us ing a clamp 3 as indicated TABLE I IGNITION SWITCH ASSEMBLY Connect the two connectors of the ig nition switch assembly and place them on the filter box in the appropriate housings Electrical system R...

Page 101: ...ling lever must be as indicated in the figures TABLE J2 PROCEDURE FOR THE CORRECT FITTING OF THE ABS CONTROL UNIT CON NECTOR 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 TABLE J3 PROCEDURE FOR THE CORRECT FITTING OF THE ABS CONTROL UNIT CON NECTOR When the connector is fully inserted the distanc...

Page 102: ...order to ensure that the connector is inserted correctly TABLE K VEHICLE GROUND The wiring of the vehicle ground cable 1 must pass under the ABS modula tor as indicated and fixed to the engine with a special screw with washer to gether with the battery ground cable CAUTION ENSURE THE CORRECT FIXING OF THE SCREW TO THE PRESCRIBED TORQUE TABLE L ECU The wiring 1 of the vehicle connec tor to be conne...

Page 103: ...e control unit support and in the cable grommet 3 on the brake pipe support left side TABLE M1 OIL PRESSURE SENSOR The wiring 1 of the oil pressure sen sor must pass behind the cooling sys tem pipes and must be fastened to one of these using a special cable grommet 4 RS 660 Tuono 660 Electrical system ELE SYS 103 ...

Page 104: ... TABLE N QUICK SHIFT The wiring 1 of the quick shift 2 must pass through the special groove in the sprocket cover as shown and behind the gear lever TABLE N1 QUICK SHIFT The wiring 1 of the quick shift must pass through the internal part of the frame seat sub frame and then the connector located inside the compart ment under the saddle on the right side must be connected Electrical system RS 660 T...

Page 105: ...adiator support TABLE O1 LAMBDA PROBES Lambda probe_2 Insert the lambda probe 2 4 in its seat pass the wiring 5 behind the exhaust manifold and on the appropriate sup port and after connecting the connec tor 6 fasten it to the clip on the support Back side TABLE A PRE ASSEMBLY OF THE CABLE GROMMET CLIP ON THE LOWER SADDLE SUP PORT CLOSURE Place the clips 1 2 3 in the points indicated RS 660 Tuono ...

Page 106: ...E 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 2 Battery ground cable wiring harness Electrical system RS 660 Tuono 660 ELE SYS 106 ...

Page 107: ...UND AND START ER MOTOR POSITIVE Pass the wiring harness as indicated The battery ground cable must be positioned un der the vehicle ground cable Ensure that the screw is provided with a washer and that it is cor rectly fixed to the prescribed torque Components present 1 Starter motor positive wiring harness 2 Battery ground cable wiring harness 3 Vehicle ground cable wiring harness RS 660 Tuono 66...

Page 108: ...egative pole of the battery TABLE B4 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 The positive wiring 5 coming from the positive pole of the battery is fixed on the lower screw of the starter relay 4 while the wiring 6 coming from the positive pole of the battery goes to...

Page 109: ...roove on the lower saddle support closure Components present 1 Battery 2 Inertia platform 3 Relay 4 Main fuse 5 Auxiliary fuses TABLE C1 CABLE GROMMET UNDER SAD DLE SUPPORT Pass the cables as indicated Position the edge protector to prevent damage to the wiring Components present 5 Auxiliary fuses RS 660 Tuono 660 Electrical system ELE SYS 109 ...

Page 110: ...e pole of the battery on the right side of the vehicle and identified by the minus sign TABLE E SADDLE SUPPORT COMPONENTS 1 Main injection relay 2 Fan relay 3 Fuel pump relay 4 Inertia platform 5 AMP control unit if present TABLE F REAR ABS SENSOR The wiring 1 of the rear ABS sensor 2 must be locked to the brake pipe with a rubber clamp 3 and the passed through the cable grommet 4 fixed to the swi...

Page 111: ... REAR ABS SENSOR The wiring 1 of the rear ABS sensor must pass through the cable grommet 6 connected to the ABS modulator support and then inside the saddle support TABLE F3 REAR ABS SENSOR Operating on the right side of the mo torcycle after connecting the connec tor 7 of the rear ABS sensor hook it to the clip 8 RS 660 Tuono 660 Electrical system ELE SYS 111 ...

Page 112: ...nsure that the wiring with the red tap ing goes to the left arrow TABLE H REAR SECTION 1 Main wiring harness 2 Rear wiring harness connector 3 Auxiliary fuses 4 Diagnostic socket connector 5 USB socket connector if present 6 Connector Electrical system RS 660 Tuono 660 ELE SYS 112 ...

Page 113: ...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 RS 660 Tuono 660 Electrical system ELE SYS 113 ...

Page 114: ...to the control unit 2 TABLE B1 CABLE ARRANGEMENT IN THE CONTROL UNIT ZONE The rubber block 3 of the secondary valve 4 must be facing as in the im age Check that the connector 5 and the safety hook of the throttle body motor are correctly inserted Electrical system RS 660 Tuono 660 ELE SYS 114 ...

Page 115: ...gine 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 Secure the gear sensor connector to the control unit support with a clamp 8 RS 660 Tuono 660 Electrical system ELE SYS 115 ...

Page 116: ...ZONE PASSAGES 1 Coil connectors must be attached to the can ister support 2 Purge valve check the correct connection of the connector 3 Injector connectors the wiring must pass under the canister pipe TABLE E FILTER BOX ZONE PASSAGES Check the correct insertion of the in take air temperature sensor connector Electrical system RS 660 Tuono 660 ELE SYS 116 ...

Page 117: ...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 RS 660 Tuono 660 Electrical system ELE SYS 117 ...

Page 118: ...enna not standard 18 Anti theft system LED 19 Front ABS sensor 20 Rear ABS sensor 21 ABS control unit 22 USB power socket not standard 23 Fan relay 24 Fan 25 Auxiliary fuses 2 2 fuses 26 Alternator 27 Voltage regulator 28 Starter motor 29 Main starter relay 30 Main fuse 31 Battery 32 Stand switch 33 Auxiliary fuses 1 1 fuse 34 Inertial sensor platform fall sens 35 Fuel pump relay 36 Injection rela...

Page 119: ...ne control unit 57 OBD connector 58 AMP provision not standard 59 Left front turn indicator USA 60 Front LED headlight 61 DRL right turn indicator 62 High beam LED module 63 Low beam LED module 64 DRL left turn indicator 65 Right front turn indicator USA 66 Engine vehicle wiring harness conn 67 Engine ground point 68 Engine head ground point 69 Diagnostics CAN 2 Storing new keys NOTE REGARDLESS OF...

Page 120: ... IMMOBILIZER ANTENNA IS DISCONNECTED YOU WILL NOT BE ABLE TO START KEY PROGRAMMING Enter the USER CODE to continue If the code entered is correct the first key is stored At this point on the digital display of the motorcycle after the automatic restart of the dynamic presentation screen a message will appear with a countdown of 20 seconds to insert the second key to be programmed Set key to OFF in...

Page 121: ...te or malfunctions or when the engine does not start Start by checking the secondary fuses in order of size from the lowest amperage fuse to the highest and then check the 30A main fuse CAUTION DO NOT ATTEMPT TO REPAIR FAULTY FUSES NEVER USE A FUSE THAT IS DIFFERENT THAN WHAT IS SPECIFIED TO PREVENT DAMAGES TO THE ELECTRICAL SYSTEM OR SHORT CIRCUITS AND THE RISK OF FIRE CAUTION A FUSE THAT BLOWS F...

Page 122: ...em F 5A fuse Positive key on power for headlamp load G 2A fuse Positive key on power for USB H 15A fuse Fan relay power feed ECU power feed fuel pump relay power feed RH and LH lambda probe power feed RH and LH injector power feed RH and LH coil power feed secondary air system valve power feed I 5A fuse Power feed for provision for anti theft system OBD power feed J 7 5A fuse Fan power feed K 20A ...

Page 123: ...8000 rpm at least three times Switch the ignition off and wait at least one minute Power Latch CAUTION THE VEHICLE SPEED MUST BE 0 km h THROUGHOUT THE CRANKSHAFT TONE WHEEL ACQUISITION PROCE DURE IN CERTAIN CASES EVEN MINOR VIBRATION PRO DUCED BY THE ENGINE WITH GEARBOX IN NEUTRAL SIDE STAND EXTENDED AND NO SPEED READING ON INSTRUMENT PANEL MAY CAUSE THE PROCEDURE TO FAIL IN THIS CASE THE PROCEDUR...

Page 124: ...INDEX OF TOPICS ENGINE ENG ...

Page 125: ... Notes 1 Retention plate fixing hex socket screws 2 12 Nm 8 85 lbf ft Pre impregnated 2 Gear selector drum fixing flanged hex screw 1 25 Nm 18 44 lbf ft 3 Gear sensor fixing round headed screws 2 6 Nm 4 43 lbf ft 4 Special screw 1 12 Nm 8 85 lbf ft RS 660 Tuono 660 Engine ENG 125 ...

Page 126: ... sixth gear 6 Toothed thrust washer 7 O ring 8 Third fourth gear 9 O ring 10 Toothed thrust washer 11 Fifth gear 12 Floating bushing for fifth gear 13 Gear primary shaft 14 Flat washer 15 thrust washer 16 First gear 17 Toothed thrust washer 18 Circlip 19 Fifth gear Engine RS 660 Tuono 660 ENG 126 ...

Page 127: ...ushing for second gear 31 Toothed thrust washer 32 Second gear 33 Transmission shaft Gearbox shafts Disassembling the gearbox To proceed with the disassembly of the gearbox it is necessary to remove the upper crankcase and then proceed as follows Remove the transmission shaft 1 along with the oil seal Remove the two screws 2 that fasten the retention plate of the selector shaft RS 660 Tuono 660 En...

Page 128: ...ankcase Unscrew the fixing screw 4 of the in dex lever Remove the fixing screw 4 along with the spring 5 and index lever 6 Remove the fixing screw 7 and ex tract the selector drum 8 from the seat of the desmodromic shaft Engine RS 660 Tuono 660 ENG 128 ...

Page 129: ... 10 from the crankcase and remove both forks 11 of the transmission shaft command Remove the guide shaft 12 of the pri mary control fork which will be re moved later from the crankcase Remove the screw 13 with relative countersunk retaining washer 14 of the desmodromic shaft bearing RS 660 Tuono 660 Engine ENG 129 ...

Page 130: ...earing 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 Partially extract the primary shaft 20 and remove the bearing 21 from the shaft itself Engine RS 660 Tuono 660 ENG 130 ...

Page 131: ...mary 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 Remove the second speed gear 1 Remove the circlip 2 securing the sixth gear RS 660 Tuono 660 Engine ENG 131 ...

Page 132: ...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 Engine RS 660 Tuono 660 ENG 132 ...

Page 133: ...ip 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 Removing the secondary shaft CAUTION FIT NEW CIRCLIPS WHEN REASSEMBLING RS 660 Tuono 660 Engine ENG 133 ...

Page 134: ...sion 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 Remove the toothed thrust washer 3 Engine RS 660 Tuono 660 ENG 134 ...

Page 135: ... 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 RS 660 Tuono 660 Engine ENG 135 ...

Page 136: ...ed 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 Engine RS 660 Tuono 660 ENG 136 ...

Page 137: ... 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 RS 660 Tuono 660 Engine ENG 137 ...

Page 138: ...move 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 Engine RS 660 Tuono 660 ENG 138 ...

Page 139: ...aring for any signs of damage or pitting and change the drum if necessary Characteristic Maximum selector shaft eccentricity 0 2 mm 0 0079 in Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears Characteristic Maximum endfloat of selector forks 0 05 mm 0 0020 in Minimum wear limit of selector fork guide p...

Page 140: ... show wear beyond the limits proceed as fol lows Insert the primary shaft 1 into the hole in the crankcase and then rotate it in wards as indicated Position the primary shaft 1 in the bearing 2 present in the crankcase as far as it will go Insert the bearing 3 on the primary shaft Position the two screws 4 complete with countersunk washers 5 and tighten to the prescribed torque Engine RS 660 Tuono...

Page 141: ...top on the bearing Rotate the desmodromic shaft to align the centring pin 8 in the indicated point and facilitate the insertion of the fork sliding shaft in the following pha ses In this way it is possible to inter cept the neutral Insert the sliding shaft 9 into the crankcase thus intercepting the fork of the primary shaft RS 660 Tuono 660 Engine ENG 141 ...

Page 142: ...g 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 Position and tighten to the prescribed torque the locking screw 15 of the sliding shaft of the forks that control the gears on the transmission shaft Engine RS 660 Tuono 660 ENG 142 ...

Page 143: ...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 centring using the pin on the shaft it self Position and tighten the fixing screw 20 of the drum to the prescribed tor que Insert the gear selector shaft 21 into the crankcase up to the stop RS 660 Tuono 660 Engine ENG 143 ...

Page 144: ... prescribed torque Position the transmission shaft 23 paying attention to the correct insertion of the forks in it Correct assembly must be as shown Rotate both ends of the transmission shaft to ensure that jamming does not occur with the primary shaft Engine RS 660 Tuono 660 ENG 144 ...

Page 145: ...n now be broken down as described Remove the retaining plate 1 by slid ing it off the selector shaft 2 after turning it Remove the spring 3 CAUTION PAY PARTICULAR ATTENTION TO THE CORRECT POSI TIONING DURING THE REASSEMBLY PHASE Starter motor RS 660 Tuono 660 Engine ENG 145 ...

Page 146: ... 3 10 Nm 7 38 lbf ft Pre impregnated 5 Free wheel on rotor SHC fixing screws M6x18 3 14 Nm 10 33 lbf ft Pre impregnated 6 Stator wiring harness support plate fixing screws M5x14 2 3 Nm 2 21 lbf ft Pre impregnated Removing the starter motor To remove the starter motor it is necessary to first remove the control unit complete with support proceeding as described Disconnect the connectors 1 from the ...

Page 147: ...l 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 RS 660 Tuono 660 Engine ENG 147 ...

Page 148: ...l unit sup port Remove the control unit support 9 Undo the fastening nuts 10 and dis connect the clutch cable 11 from the lever Remove the SAS valve 12 from its support disconnect the connector 13 and lock it laterally using rubber bands Engine RS 660 Tuono 660 ENG 148 ...

Page 149: ...ing 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 RS 660 Tuono 660 Engine ENG 149 ...

Page 150: ...e the starter motor Installing the starter motor To install the starter motor proceed as described Place the wiring 1 parallel to the start er motor insert the nut 2 and tighten it to the prescribed torque Cover the nut with the special rubber protection 3 Engine RS 660 Tuono 660 ENG 150 ...

Page 151: ...ng 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 Fit the support bracket 7 of the blow by pipe insert the screw 8 and tighten it to the prescribed torque RS 660 Tuono 660 Engine ENG 151 ...

Page 152: ... 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 CAUTION CHECK THAT THE CLUTCH FUNCTIONS CORRECTLY Engine RS 660 Tuono 660 ENG 152 ...

Page 153: ...sert 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 RS 660 Tuono 660 Engine ENG 153 ...

Page 154: ... 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 Engine RS 660 Tuono 660 ENG 154 ...

Page 155: ...h the removal of the intermediate gear it is necessary to first remove the flywheel and the starting ring gear Then remove the intermediate gear from its seat Fitting the idle gear To install the intermediate gear correctly proceed as follows Generously lubricate the gear rotation pin with engine oil RS 660 Tuono 660 Engine ENG 155 ...

Page 156: ...e 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 Using a hot air gun heat the fixing screw 1 of the safety plate 2 and re move it Remove the safety plate 2 Remove the starting ring gear 3 Engine RS 660 Tuono 660 ENG 156 ...

Page 157: ...the crankshaft with engine oil Generously lubricate the inner track of the starting ring gear with engine oil Insert the starter ring gear on the crankshaft and rotate it on both ends to check correct sliding Position the safety plate with the rela tive screw and tighten it to the prescri bed torque RS 660 Tuono 660 Engine ENG 157 ...

Page 158: ...rew M14x30 1 195 Nm 143 82 lbf ft 4 Stator SHC fixing screws M6x30 3 10 Nm 7 38 lbf ft Pre impregnated 5 Free wheel on rotor SHC fixing screws M6x18 3 14 Nm 10 33 lbf ft Pre impregnated 6 Stator wiring harness support plate fixing screws M5x14 2 3 Nm 2 21 lbf ft Pre impregnated Removing the flywheel cover To proceed with the removal of the flywheel cover proceed as described Remove the inspection ...

Page 159: ...Remove the water pump cover 3 complete with gasket 4 Remove the 8 screws 5 used to fas ten the flywheel cover Using the appropriate tool remove the flywheel cover 6 Specific tooling 020712Y Handle for removing the flywheel cov er RS 660 Tuono 660 Engine ENG 159 ...

Page 160: ... screw 2 Specific tooling 021036Y Flywheel side crankshaft locking tool After removing the rotor rotation lock ing tool remove the locking screw 2 complete with washer 3 Position the specific tool 4 on the ro tor and by screwing the left hand screw 5 on the tool itself it will be possible to extract the rotor from the crankshaft Specific tooling 020713Y Flywheel extractor Engine RS 660 Tuono 660 E...

Page 161: ...nkshaft 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 Remove the two pick up fixing screws 1 Remove retainer plate 2 of the stator wiring harness RS 660 Tuono 660 Engine ENG 161 ...

Page 162: ...the wiring harness from the cover to complete the removal Freewheel removal To proceed with the removal of the free wheel proceed as described Remove the six fixing screws 1 of the free wheel to the rotor Remove the flange 2 including the free wheel Engine RS 660 Tuono 660 ENG 162 ...

Page 163: ...r clutch Remove the free wheel from its housing and check the rollers for signs of wear Check if the outer spring is sufficiently preloaded to hold the rollers in place Check for wear on the sliding surface of the free wheel inside its housing IT IS NECESSARY TO REPLACE THE HOUSING OF THE FREE WHEEL IF DEFORMATIONS OR DEEP GROOVES ARE PRESENT ON THE SLIDING SURFACE RS 660 Tuono 660 Engine ENG 163 ...

Page 164: ...ng on the rotor with the spline previously in serted on the crankshaft Position the specific tool 3 and block the rotation of the rotor Insert the screw 4 with washer 5 Specific tooling 021036Y Flywheel side crankshaft locking tool Tighten the rotor fixing screw to the prescribed torque Remove the specific tool Specific tooling 021036Y Flywheel side crankshaft locking tool Engine RS 660 Tuono 660 ...

Page 165: ...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 Position the pick up 3 and the retain er plate 4 of the stator wiring harness Fully screw the screws 5 without tightening them RS 660 Tuono 660 Engine ENG 165 ...

Page 166: ...l and tighten the screws 5 to the prescribed torque Flywheel cover installation To proceed with the installation of the flywheel cover proceed as described If removed during the disassembly phase position the two centring pins 1 on the crankcase Position the gasket 2 on the crank case Position the cover 3 on the crank case Engine RS 660 Tuono 660 ENG 166 ...

Page 167: ...osition 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 Screw the cover fixing screws of the flywheel cover water pump cover to the prescribed torque RS 660 Tuono 660 Engine ENG 167 ...

Page 168: ... the flywheel cover Tighten the inspection cap to the pre scribed torque Clutch side CLUTCH Pos Description Type Quantity Torque Notes 1 Clutch fastening nut 1 175 Nm 129 07 lbf ft 2 Screws for springs M6 3 10 Nm 7 37 lb ft Engine RS 660 Tuono 660 ENG 168 ...

Page 169: ...llows Remove the cap dipstick 1 for check ing the engine oil level Remove the nine screws 2 used to fasten the clutch cover Remove the clutch cover 3 Remove the gasket 4 of the clutch cover Take care when recovering the two centring pins of the clutch cover RS 660 Tuono 660 Engine ENG 169 ...

Page 170: ...nts 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 Remove the washer 9 Engine RS 660 Tuono 660 ENG 170 ...

Page 171: ...essively 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 ALWAYS PRO CEED GRADUALLY AND PROGRESSIVELY ON EACH SCREW Remove the thrust plate 2 Remove the three springs 3 RS 660 Tuono 660 Engine ENG 171 ...

Page 172: ...en disc B Remove the second drive disc A with reduced friction material Remove the five driven discs C alternating with the five drive discs D Remove the nitrided drive disc E Remove the turned drive disc F Remove the disc spring G Remove the washer H Remove the driven disc C Remove the drive disc I it is a different colour than the others Engine RS 660 Tuono 660 ENG 172 ...

Page 173: ...r 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 RS 660 Tuono 660 Engine ENG 173 ...

Page 174: ... Remove the clutch hub 9 Remove the washer 10 Remove the clutch housing 11 Remove the roller cage 12 and the spacer 13 Engine RS 660 Tuono 660 ENG 174 ...

Page 175: ...ch housing Check the clutch bell for damage and wear that may result in clutch irregular operation If necessary replace the bell Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness Check the primary driven gear for damage and wear and if necessary replace the primary driven gear and the clutch bell all together Make sure there is not e...

Page 176: ...clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation If neces sary replace the hub Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS Check the springs for signs of damage and replace them if necessary Measure the free length of the clutch springs and replace them if necessa ry Characteristic Minimum wear limit with indivi...

Page 177: ... operations described for removal but in the reverse order Insert the washer 1 on the primary shaft Insert the roller cage 2 and the spacer 3 on the housing Insert the clutch housing 4 together with the roller cage and spacer on the primary shaft of the gearbox Insert the washer 5 RS 660 Tuono 660 Engine ENG 177 ...

Page 178: ...ert the nut 8 and tighten it to the specified torque blocking rotation of the hub using the designated tool Specific tooling 9100896 Clutch bell stopper Crimp the three edges of the retaining washer on the nut Insert the drive disc I it is a different colour than the others Insert the driven disc C Insert the washer H Insert la disc spring G paying careful attention to ensure the correct direction...

Page 179: ...c A with reduced friction material Insert the driven disc B Insert the first drive disc A with reduced friction material Insert the three retaining springs 9 on the thrust plate ensuring that the ma chined part indicated by the arrow is facing inwards Insert the clutch push rod 10 on the thrust plate RS 660 Tuono 660 Engine ENG 179 ...

Page 180: ...ve the teeth that mesh with the drive disc and will therefore not be placed on top of it Insert the thrust plate 11 making sure that the three hub columns are centered in relation to the holes as indicated WARNING INCORRECT POSITIONING OF THE PLATE ON THE HUB CAN CAUSE THE CLUTCH TO BREAK Insert the three springs 12 Engine RS 660 Tuono 660 ENG 180 ...

Page 181: ...E THREE SCREWS ALWAYS PROCEED GRADUALLY AND PRO GRESSIVELY ON EACH SCREW Tighten the three screws securing the thrust plate to the specified torque fol lowing the order A B C Installing the clutch cover Before installing the clutch cover if removed dur ing the disassembly phase restore the cover com ponents as follows Place the gasket 1 of the blow by sys tem on the crankcase as indicated RS 660 T...

Page 182: ...he specified torque Place the oil seal 4 inside of the clutch cover and fully insert it with the special tool Specific tooling 021042Y Oil seal and clutch shaft bearing and gear shaft punch Place the washer 5 paying attention to the mounting direction Insert the circlip 6 Engine RS 660 Tuono 660 ENG 182 ...

Page 183: ...artially 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 Using a hair dryer heat the housing seat of the upper clutch control shaft bearing RS 660 Tuono 660 Engine ENG 183 ...

Page 184: ...te the inside of the oil seal 10 and insert it on the clutch control shaft Using the special tool fully insert the oil seal Specific tooling 021042Y Oil seal and clutch shaft bearing and gear shaft punch To proceed with the installation of the clutch cover proceed as described If removed during the disassembly phase position the two centring pins 11 on the crankcase Engine RS 660 Tuono 660 ENG 184...

Page 185: ...mended to facili tate the positioning of the cover Rotate the clutch rod bringing the toothing to the left as indicated Position the cover 14 on the crank case Insert the eight screws 15 indicated for fixing the clutch cover and tighten them to the specified torque RS 660 Tuono 660 Engine ENG 185 ...

Page 186: ...missing screw 19 fixing the cover and tighten it to the specified torque Insert and screw the engine oil level cap dipstick 20 Crankshaft check Characteristic Crankshaft axial clearance crankcase 0 40 0 18 mm 0 0157 0 0070 in Maximum radial play between main bushings and crankpins 0 07 mm 0 00275 in Engine RS 660 Tuono 660 ENG 186 ...

Page 187: ... 012 0 020 in Maximum radial play of crankpin 0 08 mm 0 0031 in Inspecting pistons PISTON CYLINDER COUPLING Selection A B Selection Cylinder 80 998 81 006 mm 81 006 81 014 mm Piston 80 941 80 951 mm 80 951 80 961 mm Coupling clearance 0 047 0 065 mm 0 045 0 063 mm CAUTION THE MEASUREMENT OF THE PISTON DIAMETER IS PERFORMED AT 6 mm 0 24 in FROM ITS BASE Characteristic Aperture tolerance of the firs...

Page 188: ...kshaft The permitted crankshaft connecting rod balancing class combinations are listed in the following table CRANKSHAFT CONNECTING ROD BALANCING CLASSES Crankshaft weight classes Connecting rod weight classes marking weight E1 E1 301 5 g 304 49 g E2 E2 304 5 g 307 49 g E3 E3 307 5 g 310 49 g E4 E4 310 5 g 313 49 g E5 E5 313 5 g 316 5 g Every single connecting rod regardless of the weight class ca...

Page 189: ...e connecting rod upper area Construction features CRANK PINS Class X Class Y Class Z Min 35 885 mm Min 35 880 mm Min 35 874 mm Max 35 880 mm Max 35 874 mm Max 35 869 mm CONNECTING ROD CLASSES Class 1 Class 2 Min 39 010 mm Min 39 017 mm Max 39 016 mm Max 39 022 mm CONNECTING ROD BUSHINGS BLUE YELLOW GREEN 1 547 mm 1 552 mm 1 557 mm 1 552 mm 1 557 mm 1 562 mm Bushing selection CRANKSHAFT BUSHINGS Cr...

Page 190: ... 960 mm Min 1 964 mm Min 1 968 mm Min 1 972 mm Min 1 976 mm Max 1 964 mm Max 1 968 mm Max 1 972 mm Max 1 976 mm Max 1 980 mm The RED and BROWN bushings are for emergency use and are not available as spare parts CRANKCASE CATEGORIES CRANKSHAFT Class A Class B Min 39 943 mm Min 39 949 mm Max 39 949 mm Max 39 955 mm MAIN JOURNAL CRANKSHAFT Class A Class B Min 35 986 mm Min 35 992 mm Max 35 992 mm Max...

Page 191: ...D 0 062 0 040 mm Bushing BLUE 0 061 0 039 mm Countershaft Class G Bushing BLACK 0 065 0 043 mm Bushing RED 0 059 0 042 mm Construction features MAIN BUSHINGS COUNTERSHAFT RED BLUE YELLOW BLACK Min 1 992 mm Min 1 996 mm Min 2 000 mm Min 1 988 mm Max 1 997 mm Max 2 001 mm Max 2 005 mm Max 1 993 mm CRANKCASE CATEGORIES COUNTERSHAFT F G Min 27 500 mm Min 27 507 mm Max 27 507 mm Max 27 514 mm MAIN JOUR...

Page 192: ... COVER Pos Description Type Quantity Torque Notes 1 Spark plugs 2 12 Nm 8 85 lbf ft 2 Head cover fastening screws 4 10 Nm 7 38 lbf ft 3 TE flanged coil fixing screw M6x16 2 12 Nm 8 85 lbf ft Engine RS 660 Tuono 660 ENG 192 ...

Page 193: ...Nm 4 43 lbf ft 5 Stud bolts M10 4 10 Nm 7 38 lbf ft 6 Flanged nut fixing cylinder head M10 6 30 Nm 22 12 lb ft Pre tightening lu bricate with MOLY KOTE G RAPID PLUS 6 Flanged nut fixing cylinder head M10 6 180 Tightening Removing the head cover To proceed with removing the head cover pro ceed as described Remove the four fixing screws 1 of the head cover and the relative damper pads 2 Remove the h...

Page 194: ...oving 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 At this point proceed as described Remove the two external fixing screws 1 of the head Remove the six fixing nuts 2 of the head Engine RS 660 Tuono 660 ENG 194 ...

Page 195: ...rhead 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 Remove the twelve fixing screws 1 of the cam tower 2 and the support plate 3 of the fixed chain slider RS 660 Tuono 660 Engine ENG 195 ...

Page 196: ...the ex haust camshaft removing the timing chain from the gear on the shaft itself CAUTION PROCEED WITH CAUTION DURING THE REASSEMBLY PHASE SINCE THE CAMSHAFTS ARE DIFFERENT Removing the valves To proceed with the removal of the valves proceed as described Position the head in a vice using the special protective jaws INTAKE VALVES CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE INTAKE VALVE BUT ...

Page 197: ...ppet 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 RS 660 Tuono 660 Engine ENG 197 ...

Page 198: ... 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 Remove the valve 6 Engine RS 660 Tuono 660 ENG 198 ...

Page 199: ...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 Using a magnet remove the calibrated pad 10 RS 660 Tuono 660 Engine ENG 199 ...

Page 200: ...haust 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 Remove the upper cup 12 Engine RS 660 Tuono 660 ENG 200 ...

Page 201: ...ove 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 Position the head in a vice using the special protective jaws INTAKE VALVES RS 660 Tuono 660 Engine ENG 201 ...

Page 202: ...ower 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 CAUTION THE SPRINGS MUST BE POSITIONED WITH THE MORE COMPRESSED PART OF THE SPIRALS FACING THE HEAD Engine RS 660 Tuono 660 ENG 202 ...

Page 203: ...he 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 Release the springs and remove the tool RS 660 Tuono 660 Engine ENG 203 ...

Page 204: ...at 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 Position the lower cap 9 Engine RS 660 Tuono 660 ENG 204 ...

Page 205: ...sert 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 Position the upper cup 13 RS 660 Tuono 660 Engine ENG 205 ...

Page 206: ... 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 Release the spring and remove the tool Using a punch with a rubber mallet check that the valve is not blocked Engine RS 660 Tuono 660 ENG 206 ...

Page 207: ...E 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 RS 660 Tuono 660 Engine ENG 207 ...

Page 208: ... ft 4 Secondary air cover fixing screws M5x16 3 6 Nm 4 43 lbf ft 5 Stud bolts M10 4 10 Nm 7 38 lbf ft 6 Flanged nut fixing cylinder head M10 6 30 Nm 22 12 lb ft Pre tightening lu bricate with MOLY KOTE G RAPID PLUS 6 Flanged nut fixing cylinder head M10 6 180 Tightening Removing the chain tensioner To proceed with the removal of the chain tension er proceed as described Remove the cap 1 Engine RS ...

Page 209: ... 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 RS 660 Tuono 660 Engine ENG 209 ...

Page 210: ...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 Remove the fixed slider 1 from its seat in the crankcase Remove the fixing screw 2 of the mo bile slider Engine RS 660 Tuono 660 ENG 210 ...

Page 211: ... installation of the chain ten sioner proceed as described After verifying correct operation use a rubber hammer to arm the chain ten sioner Insert the chain tensioner 1 complete with O Ring 2 Insert the special screw 3 complete with metal washer 4 RS 660 Tuono 660 Engine ENG 211 ...

Page 212: ...fied 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 Tighten the plug to the prescribed tor que Cam timing Timing NOTE Engine RS 660 Tuono 660 ENG 212 ...

Page 213: ... ro tate the crankshaft and identify in the point indicated the hole in the crank case to insert the first centring pin 1 Specific tooling 020851Y Camshaft timing pin Position the cam shafts 2 on the head The exhaust camshaft has two grooves in the indicated point The correct positioning is determined by the holes for the insertion of the pins facing up wards Generously lubricate the camshafts at ...

Page 214: ...rews to the prescribed torque following the indicated se quence Position the timing gear 5 complete with chain on the exhaust camshaft centring the slotted holes with respect to the fixing points of the gear itself Insert the second centring pin 6 on the exhaust camshaft at the point shown Specific tooling 021043Y Camshaft timing pin 2 pieces Engine RS 660 Tuono 660 ENG 214 ...

Page 215: ...nsertion point of the third pin 9 on the cam tower Specific tooling 021044Y Intake camshaft disarming lever 021043Y Camshaft timing pin 2 pieces Remove the pin position the timing gear 10 complete with chain on the intake camshaft centring the slotted holes with respect to the fixing points of the gear itself and reposition the pin Specific tooling 021043Y Camshaft timing pin 2 pieces RS 660 Tuono...

Page 216: ... the slotted holes of the gears them selves Insert and hand tighten one screw 11 of the timing gear onto the intake shaft Position the plate 12 complete with the chain slider and after inserting the screws tighten them to the prescribed torque After verifying correct operation use a rubber hammer to arm the chain ten sioner Engine RS 660 Tuono 660 ENG 216 ...

Page 217: ...om 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 RS 660 Tuono 660 Engine ENG 217 ...

Page 218: ...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 Engine RS 660 Tuono 660 ENG 218 ...

Page 219: ...y Torque Notes 1 Connecting rod screws M 4 1 15 Nm 11 06 lbf ft 2 20 Nm 110 14 75 lbf ft 110 Lubricate with Pankl oil Installing the cylinder head To proceed with the installation of the head pro ceed as described Insert the gasket 1 RS 660 Tuono 660 Engine ENG 219 ...

Page 220: ...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 Insert the two external screws 4 and tighten them to the specified torque Engine RS 660 Tuono 660 ENG 220 ...

Page 221: ...on 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 Position the gaskets 4 of the cover RS 660 Tuono 660 Engine ENG 221 ...

Page 222: ...er 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 Engine RS 660 Tuono 660 ENG 222 ...

Page 223: ... screws M8x60 4 22 5 27 5 Nm 16 60 20 28 lb ft Lubricate with oil 7 Crankcase halves mating threaded hex screws M6x30 4 10 8 13 2 Nm 7 97 9 74 lb ft 8 Pistons lubrication jets SHC fixing screw M5x14 2 5 4 6 6 Nm 3 98 4 87 lb ft 9 Bearings stopper countersunk hex head screws 3 9 11 Nm 6 64 8 11 lb ft Pre impregnated 10 Stud bolts M10 6 18 22 Nm 13 28 16 23 lbf ft H 63 5 0 5 mm 2 50 0 02 in Pre impr...

Page 224: ... Remove the thirteen M8 screws 4 and recover the copper washers where present Remove the six M10 screws 5 Remove the lower crankcase 6 Engine RS 660 Tuono 660 ENG 224 ...

Page 225: ...cases after having inserted all gearbox components the crankshaft complete with connecting rods pistons proceed as described Generously lubricate the counter shaft bushings Insert the counter shaft 1 on the crankcase checking the correct posi tion determined by the references visi ble on the gears Generously lubricate the crankshaft and counter shaft at the rotation points of the bushings RS 660 T...

Page 226: ...ated 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 Engine RS 660 Tuono 660 ENG 226 ...

Page 227: ...inage plug 1 20 Nm 14 75 lbf ft 7 Sump fixing flanged hex screw M6 10 12 Nm 8 85 lbf ft 8 Oil pump fastening screws M5 2 6 Nm 4 43 lbf ft 9 Oil pump gear fastener screw 1 12 Nm 8 85 lbf ft Oil pump Removing To proceed with the removal of the oil pump it is necessary to first remove the flywheel cover the rotor and the starter ring gear Then proceed as described Place a rag or piece of paper under ...

Page 228: ...ew 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 Remove the oil pump 6 Engine RS 660 Tuono 660 ENG 228 ...

Page 229: ...Insert and tighten the two oil pump fix ing screws 2 to the prescribed torque Place a rag or piece of paper under the oil pump to prevent the plug from falling into the engine Then insert the gear 3 of the oil pump aligning the hole with the machining on the pump shaft and insert the pin 4 Position the screw 5 complete with spring washer 6 RS 660 Tuono 660 Engine ENG 229 ...

Page 230: ...ed 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 Remove the oil sump 2 Remove the fixing screw 3 of the oil sump gasket Engine RS 660 Tuono 660 ENG 230 ...

Page 231: ...e oil sump pro ceed as described Check and if necessary replace the O rings 1 on the rose pipe 2 before in serting it at the same time as the gasket 3 as indicated Block the movement of the gasket by temporarily positioning two opposite screws as shown and after inserting the fixing screw 4 tighten it to the prescribed torque After removing the gasket centring screws position the sump 5 RS 660 Tuo...

Page 232: ...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 Remove the overpressure valve by un screwing it from its seat Engine RS 660 Tuono 660 ENG 232 ...

Page 233: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 234: ...Power supply RS 660 Tuono 660 P SUPP 234 ...

Page 235: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 236: ...nti vibration weight M5x50 2 Nm lb ft Right hand light switches fixing screw M5 1 4 Nm 2 95 lb ft Left hand light switches fixing screw M5 1 4 Nm 2 95 lb ft Removing The motorcycle is equipped with semi handlebars and for the removal operate as described RIGHT SEMI HANDLEBAR Unscrew the fixing screw 1 and re move the anti vibration weight 2 Suspensions RS 660 Tuono 660 SUSP 236 ...

Page 237: ...e 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 Keeping the semi handlebar 7 still remove the locking screw 8 RS 660 Tuono 660 Suspensions SUSP 237 ...

Page 238: ...ebar 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 Loosen the locking screw 4 of the light switch Suspensions RS 660 Tuono 660 SUSP 238 ...

Page 239: ...cking screw 7 Slide off the light switch and the clutch control from the semi handlebar and remove it To fit the semi handlebar repeat the procedures previously described in reverse order and finally tighten the six semi handlebar screws to the specified torque RS 660 Tuono 660 Suspensions SUSP 239 ...

Page 240: ... the setting can be modified for specific needs according to vehicle use Each fork is equipped with an upper adjustment adjuster 1 to set the rebound damping and an upper nut 2 to adjust the spring pre loading TO AVOID DAMAGE DO NOT FORCE THE ADJUSTERS BEYOND THE MAXIMUM SETTING PO SITION IN EITHER DIRECTION SET THE SAME SPRING PRE LOAD AND HYDRAULIC DAMPING SETTING FOR BOTH STANCHIONS RIDING THE ...

Page 241: ... 2 notches SETTING FOR SPORTS USE Specification Desc Quantity Rebound damping adjustment screw 1 Unscrew 10 clicks from fully closed Spring pre loading nut 2 Fully loosened Stems A protrusion from top plate excluding cover 2 notches clockwise anticlockwise Removing the fork legs After positioning the motorcycle on the front stand under the headstock 1 to remove the stanchions it is necessary to fi...

Page 242: ... 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 Working from below as shown un screw the screws 5 securing the stan chion to the lower triple clamp Suspensions RS 660 Tuono 660 SUSP 242 ...

Page 243: ...the stanchion protrusion referring to the Adjustment paragraph in the Suspensions chapter Draining oil NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE STANCHION BUT APPLY TO BOTH Clamp the forks in a vice with protected jaws taking care not to damage them Fully tighten the adjustment screw 1 of the rebound damping Specific tooling AP8140149 Guard for assembly operations RS 660 Tuono 660 Suspension...

Page 244: ...cific tool 4 fixed to the pre loading pipe 5 compress the spring With the help of a second worker insert the separator plate 6 under the cap retaining nut 7 Specific tooling 020888S Pre load tube clamp AP8140148 Plunger spacer separator plate Ensure that the cap 8 cannot rotate and then loosen the nut 7 Suspensions RS 660 Tuono 660 SUSP 244 ...

Page 245: ...e 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 RS 660 Tuono 660 Suspensions SUSP 245 ...

Page 246: ...GINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE Disassembling the fork Using the special protective jaws block the stanchion horizontally in a vice Extract the dust guard 12 Remove the seeger ring 13 from in side the sleeve Pull the sleeve repeatedly towards yourself in order to remove it from the stanchion Suspensions RS 660 Tuono 660 SUSP ...

Page 247: ...over the container where the oil was previously collected At this point completely unscrew the plunger 18 and remove it allowing the screw with its copper washer to fall inside the container and allowing the residual oil left inside the stanchion to drain completely Checking the components stanchion Check that the sliding surface is not scratched or scored Any scoring can be removed by sanding wit...

Page 248: ...aking sure that the length is within the acceptable limits If not replace the springs MINIMUM LENGTH OF FREE SPRING 720 2 3 mm 28 35 0 12in Reassembling the fork NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE STANCHION BUT APPLY TO BOTH Block the stanchion in the vice and us ing appropriate protections and paper tape protect the cutting edges of the machining so as not to damage the dust cover an...

Page 249: ... Insert the seeger ring 2 Insert the oil seal 3 Insert the ring 4 Insert the guide bush 5 RS 660 Tuono 660 Suspensions SUSP 249 ...

Page 250: ...ith 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 Then tighten the plunger locking screw to the prescribed torque Suspensions RS 660 Tuono 660 SUSP 250 ...

Page 251: ...cial tool complete with striking weight insert the oil seal cor rectly in its seat Specific tooling AP8140145 Oil seal assembly tool AP8140146 Weight Position the safety seeger ring in its seat Insert the dust guard into its housing correctly Filling oil NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE STANCHION BUT APPLY TO BOTH RS 660 Tuono 660 Suspensions SUSP 251 ...

Page 252: ...GHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Specific tooling AP8140149 Guard for assembly operations Oil level 98 mm 3 86 in from the edge of the sleeve without spring or pre loading tube THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Characteristic Fork oil 468 cm ...

Page 253: ...e plunger to allow the plate 15 to be inserted under the cap stop nut Specific tooling AP8140150 Bored shaft for bleeding plunger air AP8140148 Plunger spacer separator plate Position the upper plate 16 as shown Specific tooling AP8140150 Bored shaft for bleeding plunger air AP8140148 Plunger spacer separator plate Before positioning the cap adjust the hydraulic regulator screw so that the interna...

Page 254: ...Ensure that the cap 17 cannot rotate and then tighten the nut 18 Compress the spring and remove the plate 15 Lift the sleeve and screw it on the cap manually Position the stanchion in the vice pro vided with adequate protections and tighten the cap to the prescribed tor que Upper steering yoke Suspensions RS 660 Tuono 660 SUSP 254 ...

Page 255: ...r 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 control and the clutch control keeping the semi handlebar 1 still unscrew the screws 2 Remove the fixing bearing 3 Remove the washer 4 Loosen the locking screws 5 of the forks RS 660 Tuono 660 Suspensions SUSP 255 ...

Page 256: ...sary 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 Then proceed as described Remove the steering safety plate 1 Remove the upper steering ring nut 2 using the special tool Suspensions RS 660 Tuono 660 SUSP 256 ...

Page 257: ...ng 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 Installing Insert the lower triple clamp 1 from below RS 660 Tuono 660 Suspensions SUSP 257 ...

Page 258: ...t Rotate the steering yoke all the way to the left and right to check that the ro tation is smooth and without jamming In the event of particular resistance or jamming remove the steering yoke and check the integrity of the bearings inside the steering headstock Specific tooling AP8140190 Steering tightening tool Insert the rubber shim 3 Screw the upper steering ring nut 4 and align the grooves to...

Page 259: ...d grip external end The handlebar resistance to rotation must be of 250 100 g 0 55 0 22 lb in both directions Adjust if clearance is detected NOTE THE STEERING COLUMN RESISTANCE TO ROTATION MUST BE PERFORMED IN THE TWO OPPOSITE ROTATION DIRECTIONS Loosen the fixing screws 1 of the stanchions Unscrew and remove the fixing bush 2 of the upper clamp RS 660 Tuono 660 Suspensions SUSP 259 ...

Page 260: ...ing the special tool in order to re peat the steering assembly tightening procedure in the correct way Pre tighten the ring nut 5 to 60 Nm 44 25 lbf ft Turn the handlebar to the left and right as far as it will go to seat the bearings Unscrew the ring nut and tighten it again to 40 5 Nm 29 50 3 68 lbf ft Reassemble the previously removed components and check the handlebar resistance to rotation th...

Page 261: ...forehand Then proceed as described Unscrew and remove the safety plate 1 Unscrew and remove the counter lock ring 2 using the appropriate tool Specific tooling AP8140190 Steering tightening tool Remove the rubber shim 3 Unscrew and remove the ring nut 4 using the special tool supporting the lower triple clamp Specific tooling AP8140190 Steering tightening tool RS 660 Tuono 660 Suspensions SUSP 261...

Page 262: ... 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 Suspensions RS 660 Tuono 660 SUSP 262 ...

Page 263: ...ring bearing After removing the inner bearing ring 11 complete with balls from the head stock tube heat the lower bearing seat 12 with a hot air gun to remove it and then slide off the dust cover 13 Remove the upper seat of the lower bearing 14 from below using a stand ard bearing extractor RS 660 Tuono 660 Suspensions SUSP 263 ...

Page 264: ...n the upper and lower part of the steering headstock insert the dust seals 4 up to the stop using the appropriate punch Specific tooling 020376Y Adaptor handle 020359S 42 x 47 mm Adaptor Working both on the upper and lower part of the steering headstock insert the rotation seats of the bearings 5 up to the stop using the appropriate punch Lubricate the inserted seats with grease Specific tooling 0...

Page 265: ...er ring of the bearing 7 complete with balls on the headstock and lubricate it Supporting the lower triple clamp lu bricate the upper seat 8 of the bearing and insert it on the headstock Supporting the lower triple clamp in sert the dust seal ring 9 on the head stock RS 660 Tuono 660 Suspensions SUSP 265 ...

Page 266: ...ng the special tool pre tighten the ring nut to Nm lbf ft and then tighten it to Nm lbf ft Specific tooling AP8140190 Steering tightening tool Screw the upper steering ring nut 11 and align the grooves to be able to in sert the safety plate Insert the safety plate 12 Rear Suspensions RS 660 Tuono 660 SUSP 266 ...

Page 267: ...Shock absorbers SHOCK ABSORBER Pos Description Type Quantity Torque Notes 1 Flanged self locking shock absorber fastening nuts M10 2 50 Nm 36 87 lb ft RS 660 Tuono 660 Suspensions SUSP 267 ...

Page 268: ...Y ADJUST THE REAR SHOCK ABSORBER THE STANDARD REGULATION OF THE REAR SHOCK AB SORBER IS INTENDED TO SATISFY NORMAL TOUR DRIV ING CONDITIONS IN ANY CASE IT IS POSSIBLE TO INSERT PERSONAL SETTINGS DEPENDING ON VEHICLE UTILIZATION TO COUNT THE NUMBER OF CLICKS OF THE ADJUSTER 1 ALWAYS START FROM THE MOST RIGID SETTING COMPLETE CLOCKWISE ROTATION TO PREVENT DAMAGE TO THE ADJUSTER SCREWS 1 NEVER FORCE ...

Page 269: ... DEAL ER TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES STANDARD ADJUSTMENT FOR ROAD USE Specification Desc Quantity Spring length A 145 5 2 mm 5 72 0 078 in Shock absorber length B 306 2 mm 12 04 0...

Page 270: ... 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 Keeping the screw 4 still unscrew the nut 5 and remove the screw Remove the shock absorber 6 Suspensions RS 660 Tuono 660 SUSP 270 ...

Page 271: ...n the T shaped bushes 1 both on the swingarm and on the frame The bushes must be inserted on the right side of the motorcycle Reposition the 4 bushings 2 on the shock absorber Place the shock absorber 3 back in its seat paying attention to the adjuster which must face towards the left side of the motorcycle RS 660 Tuono 660 Suspensions SUSP 271 ...

Page 272: ...rting 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 Suspensions RS 660 Tuono 660 SUSP 272 ...

Page 273: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 274: ...ont brake disc flanged hex fixing screw M8x20 12 25 Nm 18 43 lb ft Removal To proceed with the removal of the front wheel lift the motorcycle using an appropriate centre stand remove the brake callipers and proceed as descri bed Loosen the screw 1 on the clamp of the left stanchion Chassis RS 660 Tuono 660 CHAS 274 ...

Page 275: ... 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 RS 660 Tuono 660 Chassis CHAS 275 ...

Page 276: ... the wheel remove the oil seal 5 Using special pliers remove the circlip 6 Using a generic puller proceed with the extraction of the bearing as descri bed Insert the first part of the tool A on the bearing and screw the pin B Insert the second part C by adjusting the two pins D identifying the best point of contact Chassis RS 660 Tuono 660 CHAS 276 ...

Page 277: ...RATION DESCRIBED ABOVE TO REMOVE THE BEARING ON THE OPPOSITE SIDE OF THE WHEEL Remove the internal spacer 8 REMOVAL OF EXTERNAL WHEEL COMPO NENTS To proceed with the removal of the external wheel components proceed as described Remove the six fixing screws 9 of the tone wheel front disc RS 660 Tuono 660 Chassis CHAS 277 ...

Page 278: ...STALLATION 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 INSTALLATION OF INTERNAL COMPONENTS Position the bearing 2 on the left side of the rim Chassis RS 660 Tuono 660 CHAS 278 ...

Page 279: ...0376Y 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 Specific tooling 020376Y Adaptor handle 020358Y 37 x 40 mm Adaptor Insert the spacer 4 on the right side of the rim RS 660 Tuono 660 Chassis CHAS 279 ...

Page 280: ... 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 Fit the right oil seal 7 Chassis RS 660 Tuono 660 CHAS 280 ...

Page 281: ... 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 Tighten the pin to the prescribed torque RS 660 Tuono 660 Chassis CHAS 281 ...

Page 282: ...es to check that it does not stick Rear wheel REAR WHEEL Pos Description Type Quantity Torque Notes 1 Sprocket fixing nuts M10 5 50 Nm 36 87 lb ft 2 TE flanged screws fastening rear brake disc M8x20 5 25 Nm 18 43 lb ft 3 Rear wheel axle nut M20 1 120 Nm 88 50 lbf ft Chassis RS 660 Tuono 660 CHAS 282 ...

Page 283: ...opriate 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 Undo the fastening nut 3 of the wheel Remove the nut 3 Remove the washer 4 RS 660 Tuono 660 Chassis CHAS 283 ...

Page 284: ...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 components proceed as described Remove the sprocket support 9 from the wheel 8 Remove the flexible coupling rubber inserts 10 Chassis RS 660 Tuono 660 CHAS 284 ...

Page 285: ... proceed with the removal of the internal wheel components proceed as described Using a generic puller extract the bearing as fol lows Insert the first part of the tool A on the bearing and screw the pin B Insert the second part C by adjusting the two pins D identifying the best point of contact RS 660 Tuono 660 Chassis CHAS 285 ...

Page 286: ...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 Chassis RS 660 Tuono 660 CHAS 286 ...

Page 287: ...ing 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 Remove the internal spacer 19 RS 660 Tuono 660 Chassis CHAS 287 ...

Page 288: ...ort 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 Remove the sprocket 23 Chassis RS 660 Tuono 660 CHAS 288 ...

Page 289: ...edure 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 Position the bearing 1 on the sprocket support 2 RS 660 Tuono 660 Chassis CHAS 289 ...

Page 290: ...g 020376Y Adaptor handle 020655S Adaptor 62x68 mm Insert the circlip 3 Position the oil seal 4 on the sprocket support Using the appropriate punch insert the oil seal as far as it will go Specific tooling 020376Y Adaptor handle 020655S Adaptor 62x68 mm Chassis RS 660 Tuono 660 CHAS 290 ...

Page 291: ...port 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 RS 660 Tuono 660 Chassis CHAS 291 ...

Page 292: ...proceed with the installation of the internal wheel components proceed as described Fit the bearing 10 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 Insert the circlip 12 Chassis RS 660 Tuono 660 CHAS 292 ...

Page 293: ...ing as far as it will go Specific tooling 020376Y Adaptor handle 020359S 42 x 47 mm Adaptor INSTALLATION OF EXTERNAL WHEEL COM PONENTS To proceed with the installation of the internal wheel components proceed as described Place the brake disc 14 on the rim Place the phonic wheel 15 on the rim RS 660 Tuono 660 Chassis CHAS 293 ...

Page 294: ... them to the prescribed torque in the or der indicated Position the flexible coupling rubber in serts 16 on the rim Position the complete sprocket support 17 on the rim Position the wheel 18 in its seat in serting the chain 19 on the sprocket Chassis RS 660 Tuono 660 CHAS 294 ...

Page 295: ...ide 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 Insert the nut 24 and tighten it by hand RS 660 Tuono 660 Chassis CHAS 295 ...

Page 296: ...n from the centre of the rear wheel axle along imaginary line between centres of front and rear sprockets is approximately 30 mm 1 18 in CAUTION WHEN CHECKING THE DEFLECTION OF THE CHAIN THE CHAIN MUST NOT BE ABLE TO TOUCH THE UNDERSIDE PART OF THE SWINGARM IN THE POSITION INDICATED BY THE ARROW Check that the distance set is the same on both sides Tighten the rear wheel locking nut to the prescri...

Page 297: ...ace 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 swingarm To proceed with the removal of the swingarm it is necessary to first remove the rear wheel rear mudguard and crankcase cover Then remove the screw 1 with its spring washer which fixes the left rider footrest support to the engine RS 660 Tuono 660 C...

Page 298: ...sup port to the swingarm Remove the complete footrest support 3 from the swingarm pin Remove the flat washer 4 from the swingarm pin Remove the cable gland 5 that fas tens the ABS sensor wiring harness and the rear brake hose to the frame Chassis RS 660 Tuono 660 CHAS 298 ...

Page 299: ...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 Remove the T bush 9 from the seat in the swingarm RS 660 Tuono 660 Chassis CHAS 299 ...

Page 300: ...trest support Remove the complete swingarm 12 If necessary to check or eventually replace the roller bearings in the swingarm remove the bushes 13 and the thrust washers 14 Remove the 4 gaskets 15 Using a suitable punch remove the roller bearings Specific tooling 020376Y Adaptor handle 020441S 26 x 28 mm adaptor Checking CAUTION Chassis RS 660 Tuono 660 CHAS 300 ...

Page 301: ...re limite In caso con trario sostituire il perno Eccentricita massima del perno 0 2 mm 0 0078 in Installing To proceed with the installation of the swingarm proceed as described If the roller bearings have been removed during the disassembly phase for a check or re placement proceed with the insertion by means of a special punch respecting the following measurements after having greased the contac...

Page 302: ... 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 Chassis RS 660 Tuono 660 CHAS 302 ...

Page 303: ...t be facing the swingarm Insert the T bush 8 in the swingarm Check the correct positioning of the two bushings 9 on the shock absorb er and after having positioned it in its seat keeping the screw 10 blocked tighten the nut 11 to the prescribed torque Position the complete brake calliper on the guide on the swingarm RS 660 Tuono 660 Chassis CHAS 303 ...

Page 304: ...the machined part facing the swingarm itself After positioning the washer and the nut 14 on the swingarm pin tighten it to the prescribed torque Position the fixing screw 15 of the footrest support to the engine and tight en to the prescribed torque Proceed to refit the rear mudguard the crankcase cover and the rear wheel Pinion Chassis RS 660 Tuono 660 CHAS 304 ...

Page 305: ...ed as described Remove the three fixing screws 1 of the front sprocket cover 2 taking care to recover the T bushes 3 Remove the front sprocket cover 2 disconnecting the breather pipe 4 from it Remove the fixing screw 5 of the front sprocket along with the T bush 6 and the spring washer 7 Remove the front sprocket 8 from the transmission shaft and free it from the drive chain RS 660 Tuono 660 Chass...

Page 306: ...re 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 Remove the spacer 9 from the trans mission shaft Assemble the front sprocket 2 with the drive chain 3 and insert it on the transmission shaft Chassis RS 660 Tuono 660 CHAS 306 ...

Page 307: ...the breather pipe 7 in the sprocket cover 8 as indicated After positioning the sprocket cover 8 insert the three screws 9 com plete with T bushes 10 and tighten them to the prescribed torque Restore the drive chain to the correct tension following the specific procedure described in the Adjustment paragraph Drive chain RS 660 Tuono 660 Chassis CHAS 307 ...

Page 308: ...s sembling procedures NOTE WHERE PRESENT THE HAMMERLOCK 1 MAY ALSO BE IDENTIFIED BY A SIGN 2 APPLIED IN THE MOUNTING LINES DURING MANUFACTURING To dismantle and remove the chain proceed as follows Partially remove the pins 3 using a generic chain breaker Remove the outer plate 4 Remove the outer O ring rings 5 Chassis RS 660 Tuono 660 CHAS 308 ...

Page 309: ...h may be checked with the instrument are indicated on the instrument itself There are three reference markings for each chain pitch indicated on the instrument These in dicate from right to left the correct measurements for 1 New chain with length near nominal value 2 Chain with chain stretch of 1 5 3 Chain with chain stretch of 3 which must therefore be replaced in accordance with ap plicable leg...

Page 310: ...ches the correct marking on the in strument Installing After fitting the chain on the pinion and on the crown put the inner O rings 1 back onto the hammerlock pins 2 and connect the two ends of the transmis sion chain Place the outer O rings 3 on the pins Compress the outer plate 4 using the appropriate generic tool CAUTION BE CAREFUL NOT TO COMPRESS TOO THE OUTER PLATE TOO MUCH AS THIS COULD SEIZ...

Page 311: ...e in both directions Use a generic clincher to re tighten the pins of the link checking riveting at points A Turn the pin of the specific tool 90 and re engage the link pin again checking riveting at points B Grease the chain and record the clearance RS 660 Tuono 660 Chassis CHAS 311 ...

Page 312: ...ARROW Move the vehicle forwards to check the vertical deflection of the chain in other positions the chain deflection must be constant throughout the entire rotation of the wheel if the clearance is uniform but greater or less than 30 mm 1 18 in carry out the adjustment CAUTION IF THE CLEARANCE IS GREATER IN SOME POSITIONS IT MEANS THAT SOME ELEMENTS OF THE CHAIN ARE CRUSHED OR HAVE SEIZED UP IN T...

Page 313: ...the nut 1 Check the chain clearance Chain sliders Place the vehicle on the specific rear support stand optional Check that the pad 1 is not worn or damaged Replace it with a new one if it is Also check the wear of the chain guide 2 To proceed with the removal of the chain slider remove the upper screw 3 which secures the crankcase cover to the rear mudguard Remove the four side fixing screws 4 RS ...

Page 314: ...g 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 Unscrew the fixing nut of the rider foot rest support to the frame Chassis RS 660 Tuono 660 CHAS 314 ...

Page 315: ... 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 RS 660 Tuono 660 Chassis CHAS 315 ...

Page 316: ...g 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 Remove the chain skid 15 Chassis RS 660 Tuono 660 CHAS 316 ...

Page 317: ...ain 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 RS 660 Tuono 660 Chassis CHAS 317 ...

Page 318: ...ng 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 If necessary the fitting 10 complete with protective rubber 11 can be re moved Remove the washer 12 Remove the pin 13 complete with O Ring 14 Chassis RS 660 Tuono 660 CHAS 318 ...

Page 319: ... 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 RS 660 Tuono 660 Chassis CHAS 319 ...

Page 320: ... 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 Remove the seeger ring 1 Chassis RS 660 Tuono 660 CHAS 320 ...

Page 321: ...al 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 RS 660 Tuono 660 Chassis CHAS 321 ...

Page 322: ...he 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 Remove the nut 11 complete with flat washer 12 Chassis RS 660 Tuono 660 CHAS 322 ...

Page 323: ...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 Remove the fixing screw 16 of the rear stop switch 17 and after releas ing the wiring from the cable grommet separate the protective cover 18 from the switch 17 Release the brake lever return spring 19 and remove it RS 660 Tuono 660 Chassis CHAS 323 ...

Page 324: ...e the seeger ring 23 from the peg Remove the screw 24 used to fasten the peg Extract the peg 25 and if necessary remove the rubber block 26 PASSENGER FOOTRESTS THE OPERATIONS DESCRIBED BELOW RE FER TO A SINGLE PASSENGER FOOTREST BUT ARE VALID FOR BOTH Remove the seeger ring 1 Chassis RS 660 Tuono 660 CHAS 324 ...

Page 325: ...plete 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 To remove the footrest support re move the two screws 7 Remove the footrest support 8 Stand RS 660 Tuono 660 Chassis CHAS 325 ...

Page 326: ...then nut 2 from the swing arm pin and the relative washer 3 Remove the lower screw 4 used to fasten the rider footrest support taking care to collect the spring washer 5 and the spacer 6 placed behind the stand plate Remove the rider footrest support complete with linkages of the gear Chassis RS 660 Tuono 660 CHAS 326 ...

Page 327: ...are 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 Remove the two return springs 12 from the centre stand RS 660 Tuono 660 Chassis CHAS 327 ...

Page 328: ...he plate Undo the screw 16 to remove the centre stand plate 16 and the spacer 17 NOTES FOR THE REFIT PHASE Check the correct positioning of the side stand sensor in particular that the sensor pin is engaged in the hole on the stand CAUTION INCORRECT POSITIONING OF THE SIDE STAND SENSOR CAN GENERATE THE STAND OPEN SIGNAL THERE FORE INHIBIT THE START Chassis RS 660 Tuono 660 CHAS 328 ...

Page 329: ...nd the radiator Then proceed as described After disconnecting the lambda probes connectors remove the four nuts from the stud bolts Ensure that the pin on the right side of the motorcycle cannot rotate and un screw the nut on the opposite side Take care to collect the washers on both sides Remove the complete exhaust RS 660 Tuono 660 Chassis CHAS 329 ...

Page 330: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 331: ...a traditional braking system The CORNERING mode takes into account the motorcycle s lean angle so as to maximise efficiency without endangering the rider The ABS system improves vehicle control provided that the physical limits of vehicle grip on the road are not exceeded The rider is fully responsible for riding at a suitable speed based on weather and road conditions always leaving an appropriat...

Page 332: ...D AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED HANDLEBAR TURNED ON UNEVEN OR SLIPPERY ROADS OR WITH POOR GRIP CREATES A LACK OF STABILITY DIFFICULT TO HANDLE RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADUALLY DO NOT SPEED RECKLESSLY THE VEHICLE GRIP ON THE ROAD IS SUBJECT TO LAWS OF PHYSICS WHICH NOT EVEN THE ABS SYSTEM CAN ELIMINATE When the vehicle is started after the initial instrument p...

Page 333: ...T IS VERY IMPORTANT TO CHECK THAT THE DISTANCE BETWEEN TONE WHEEL AND SENSOR IS THE ONE SPECIFIED WHERE THE MOTORCYCLE HAS AN ABS SYSTEM NON APPROVED BRAKE PADS AND TYRES COMPROMISE SMOOTH BRAKING DRASTICALLY REDUCING DRIVING SAFETY NOTE THE SYSTEM S SENSORS HAVING A SIGNIFICANT ACCURACY OF READING THE TONE WHEELS MAY GENERATE A MOTORCYCLE STOPPED AND THE ENGINE RUNNING INDICA TION OF SPEED OF SOM...

Page 334: ...9 Front brake circuit inlet solenoid valve normally open 10 Rear brake circuit inlet solenoid valve normally open 11 Front brake circuit outlet solenoid valve normally closed 12 Rear brake circuit outlet solenoid valve normally closed 13 Rear front brake circuit low pressure accumulator 14 Dual hydraulic circuit pump ABS 15 Hydraulic circuit motor 16 DC electric motor Braking system RS 660 Tuono 6...

Page 335: ... slippage exceeds the threshold the system closes the inlet valve 9 10 and opens the outlet valve 11 12 temporarily At this stage the rider cannot increase the pressure on the callipers 3 4 and the system reduces the pressure on the callipers partially Excess fluid temporarily fills the reservoir located inside the ABS modulator until the ABS pump 14 automatically activates to direct the fluid to ...

Page 336: ...nit with the vehicle wheel reads the status of the vehicle wheel spotting any possible lock A control unit 1 signals this out and adjusts the pressure in the braking circuit accordingly CAUTION WHEN THE ABS STARTS WORKING A VIBRATION IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED HANDLE BAR TURNED O...

Page 337: ...g it from the frame Remove the two rear brake pump fas tener screws 4 Remove the two rubber clamps 5 Unclip the rear brake switch 6 and rear ABS sensor 7 wiring harness from the cable grommet Remove the brake master cylinder 8 from the pumping element 9 RS 660 Tuono 660 Braking system BRAK SYS 337 ...

Page 338: ...nsor wiring Remove the two screws 12 fastening the rear brake calliper Extract the rear brake calliper 13 re leasing the brake hose from the cable grommet 14 Unscrew the two screws 15 and re move the closing bracket 16 of the radiator support which holds the front brake hoses Braking system RS 660 Tuono 660 BRAK SYS 338 ...

Page 339: ...ws 18 fastening the ABS modulator support to the frame Turn the ABS modulator slightly to fa cilitate the disconnection of the con nector 19 Rotate the ABS modulator again to ac cess the screw 20 that locks it to the support and remove it RS 660 Tuono 660 Braking system BRAK SYS 339 ...

Page 340: ... screws 23 of the brake pipes and remove the mod ulator In case the complete ABS system needs to be re moved leave the brake pipes connected remove the steering plate lower closure and proceed with the following operations Remove the calliper and rear brake master cylinder from the left side of the vehicle as shown Braking system RS 660 Tuono 660 BRAK SYS 340 ...

Page 341: ...der 28 Remove the pump and the two front brake callipers in order to proceed with the complete removal of the ABS sys tem If replacing the pipes or the modulator it is necessary to bleed the entire ABS system To bleed the ABS system optimally it is advisable to use devices such as vacuum pumps or similar WARNING WE RECOMMEND MARKING THE PIPES SO THAT THEY ARE REFITTED CORRECTLY ON THE NEW MODULATO...

Page 342: ...ement of the ABS control unit ensure that the new one has caps on all four hydraulic connections and then proceed as follows After connecting the new ABS control unit hydraulically and electrically it must be activated recognised Do a KEY ON Check that the ABS warning light flashes rapidly Do a KEY OFF followed by a KEY ON If activation has been successful the warning light should come on and flas...

Page 343: ...unit must be 7 5 mm If the initial position of the connector and of the driving lever is not as shown in the A1 image the connector will not engage properly and the measured distance will be greater approximately 12 mm In this case repeat the operation as described in the A2 A3 images We recommend creating a template in order to ensure that the connector is inserted correctly Rear brake calliper R...

Page 344: ...ear ABS sensor Make sure you have a container with adequate capacity to recover the oil and after connecting a pipe to the breather valve 3 unscrew it to allow the oil to drain out and empty the sys tem Remove the rubber grommet 4 After having adequately protected the brake calliper remove the pipe fixing screw 5 and plug the pipe itself Braking system RS 660 Tuono 660 BRAK SYS 344 ...

Page 345: ...brake calliper 7 Installing To install the rear brake calliper proceed as de scribed Position the rear brake calliper 1 on the disc Insert and tighten the two brake calliper fixing screws 2 to the prescribed tor que RS 660 Tuono 660 Braking system BRAK SYS 345 ...

Page 346: ...E CALLIPER BUT ARE VALID FOR BOTH To remove the front 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 of the front ABS sensor if present Make sure you have a container with adequate capacity to recover the oil suitably protect the brake calliper and after connecting a pipe to the breather valve 2 unscr...

Page 347: ...g screws 4 Remove the brake calliper 5 Installing NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH To install the front brake calliper proceed as de scribed Position the front brake calliper 1 on the disc RS 660 Tuono 660 Braking system BRAK SYS 347 ...

Page 348: ...t the brake hose the special screw 3 and tighten it to the prescribed torque Fill with oil and bleed the system Rear brake disc Removal To remove the rear brake disc after removing the wheel proceed as described Remove the five fixing screws 1 of the tone wheel and of the brake disc on the rim Braking system RS 660 Tuono 660 BRAK SYS 348 ...

Page 349: ...s with a micro meter in different points If the minimum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 5 mm 0 18 in Using a dial gauge check that the max imum oscillation of the disc does not exceed the tolerance otherwise re place it Disc oscillation tolerance 0 1 mm 0 0039 in RS 660 Tuono 660 Braking system BRAK SYS 349...

Page 350: ...tallation WARNING THE FLAT SURFACE MUST SUPPORT THE RIM WHILE THE UNLOADED AND PAINTED SURFACE MUST BE FAC ING OUTSIDE Position the tone wheel 2 on the rim making sure it is in the correct direction of installation WARNING THE CURVED SURFACE ON THE INSIDE MUST BE FACED OUTSIDE AS INDICATED Insert the five screws 3 and tighten them to the specified torque in the in dicated order A B C D E Front bra...

Page 351: ...e disc on the rim Remove the tone wheel 2 if applica ble Remove the brake disc 3 Disc Inspection The following operations must be car ried out with the brake discs fitted on the wheel they refer to a single disc but are valid for both Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum thickness even in a single point RS 660 Tuono 660 B...

Page 352: ...aced with new discs proceed as described to carry out the fitting THE FOLLOWING OPERATIONS REFER TO A SINGLE DISC BUT APPLY TO BOTH Position the brake disc 1 on the rim making sure it is in the correct direction of installation CAUTION IN CORRESPONDENCE WITH ONE OF THE LATCHES OF THE FLOATING DISC AN ARROW IS SHOWN THAT INDI CATES THE WHEEL S ROTATION DIRECTION AND CON SEQUENTLY THE CORRECT POSITI...

Page 353: ... 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 CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE CALLIPER BUT APPLY TO BOTH To remove the front brake pads proceed as de scribed Remove the cotter pin 1 from the pin Remove the pin 2 RS 660 Tuono 6...

Page 354: ... 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 CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE CALLIPER BUT APPLY TO BOTH To fit the front brake pads proceed as described Insert the brake pads 1 in the calliper Braking system RS 660 Tuono 660 BRAK SYS 354 ...

Page 355: ... in the pin Check the correct operation of the brake system Rear brake pads Removal To remove the rear brake pads remove the rubber grommet freeing the ABS sensor wiring harness from the brake hose and then proceed as descri bed Remove the two brake calliper fixing screws 1 RS 660 Tuono 660 Braking system BRAK SYS 355 ...

Page 356: ...he 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 Remove the pin 4 Remove the safety spring 5 Braking system RS 660 Tuono 660 BRAK SYS 356 ...

Page 357: ...GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE Installing To fit the rear brake pads proceed as described With the brake calliper in hand and then removed from its position insert the brake pads 1 into the calliper Position the spring 2 Insert the pin 3 RS 660 Tuono 660 Braking system BRAK SYS 357 ...

Page 358: ...ing procedure it is also necessary to operate the brake pedal a few times with the bleeder device connected approximately five times for each wheel circuit Front TRADITIONAL BLEEDING SYSTEM Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper The presence of air is signalled by the spong...

Page 359: ...t fully pressed Loosen the bleed valve by a 1 4 turn so that the brake fluid flows into the con tainer this will release the tension on the brake lever and it which will make it arrive at the end stop Close the bleed valve before arriving at the end of the stroke with the lever Repeat the operation until the are no air bubbles in the fluid going into the container NOTE WHILE BLEEDING THE HYDRAULIC...

Page 360: ...e of air is signalled by the sponginess of the brake and by poor braking CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING THE BRAKE CALLIPER TO RESTORE THE BRAKING SYSTEM TO ITS REGULAR USE CONDITIONS SO THAT THE HYDRAULIC CIRCUIT IS AIR PURGED NOTE THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NEC...

Page 361: ...l res ervoir cap Refit the rubber protection cover BLEEDING SYSTEM WITH DIAGNOSTIC INSTRUMENT 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 REAR BLEEDING in the section SETTINGS The pump starts running While the pump is performing a rotation cycle ope...

Page 362: ...ews 2 of the U bolt 3 and remove it supporting the brake pump Remove the brake pump complete 4 Checking Remove the master cylinder and check for scratches rust or holes in the mas ter cylinder wall and the external wall of each piston Check that the anti dust covers are not damaged if damaged replace them Check the condition of the piston re place it if damaged Braking system RS 660 Tuono 660 BRAK...

Page 363: ...p it is necessary to previously empty the oil from the system Then proceed as described Remove the safety O ring 1 from the pin that blocks the brake pump control rod Rotate the pin 2 to release the brake pump control rod and slide it out in or der to remove it Undo the fastener screw 3 of the oil pipe Ensure that the screw 4 cannot rotate and unscrew the nut 5 to release the oil reservoir from th...

Page 364: ... Remove the two rear brake pump fas tener screws 6 at the rider footrest support Remove the brake pump 7 complete with reservoir Braking system RS 660 Tuono 660 BRAK SYS 364 ...

Page 365: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 366: ...5 Oil pressure regulation valve 1 42 Nm 30 98 lbf ft 6 Drainage plug 1 20 Nm 14 75 lbf ft 7 Sump fixing flanged hex screw M6 10 12 Nm 8 85 lbf ft 8 Oil pump fastening screws M5 2 6 Nm 4 43 lbf ft 9 Oil pump gear fastener screw 1 12 Nm 8 85 lbf ft Removal To proceed with the removal of the water pump proceed as described Remove the five fixing screws 1 of the water pump cover Cooling system RS 660 ...

Page 367: ...omplete 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 RS 660 Tuono 660 Cooling system COOL SYS 367 ...

Page 368: ...ing To proceed with the installation of the water pump proceed as described Apply a light coat of grease to the in side of the oil seal 1 Using the special punch fully seat the oil seal on the cover Specific tooling 020376Y Adaptor handle 020414Y 28 mm punch Cooling system RS 660 Tuono 660 COOL SYS 368 ...

Page 369: ...t washer 3 on the water pump gear Apply a light coat of grease to the sur face of the flat washer Screw the first component of the seal ring installation tool A onto the gear of the water pump Specific tooling 021037Y Water pump seal insertion tool RS 660 Tuono 660 Cooling system COOL SYS 369 ...

Page 370: ...ling ring 4 Insert the second part of the tool B and the nut C Specific tooling 021037Y Water pump seal insertion tool Ensure that the pin A cannot rotate and then tighten the nut until the seal ing ring is fully seated Cooling system RS 660 Tuono 660 COOL SYS 370 ...

Page 371: ...essary to remove the side and lower fairings Then proceed as de scribed Remove the expansion tank cap 1 Remove the radiator cap 2 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 RS 660 Tuono 660 Cooling system COOL SYS 371 ...

Page 372: ...clamp disconnect the pipe 4 from the radiator Empty the filler tank of any coolant left inside After unscrewing the three screws 5 remove the internal fairing complete with filler tank Release the hose clamp 6 and dis connect the pipe 7 Cooling system RS 660 Tuono 660 COOL SYS 372 ...

Page 373: ...d dis connect the pipe 11 from the thermo static valve fitting Ensure that the screw 12 cannot ro tate and unscrew the nut 13 fastening the radiator to the support bracket tak ing care to collect the T bushing Release the hose clamp 14 and dis connect the pipe 15 RS 660 Tuono 660 Cooling system COOL SYS 373 ...

Page 374: ...iator 17 sufficiently to be able to access the electric fan connector 18 and disconnect it Removing the expansion tank To remove the expansion tank it is necessary to remove the side and lower fairings Then proceed as described Remove the expansion tank cap 1 Remove the radiator cap 2 Cooling system RS 660 Tuono 660 COOL SYS 374 ...

Page 375: ... 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 Empty the filler tank of any coolant left inside Remove the vent tube 5 from the ca ble grommet located on the internal fairing RS 660 Tuono 660 Cooling system COOL SYS 375 ...

Page 376: ...oint indicated After reconnecting all pipes and filling the system with the indicated quantity of coolant check that there are no leaks in the coupling points of the pipes See also Capacities Thermostatic valve Removing To remove the thermostatic valve it is necessary to previously drain the cooling system Then pro ceed as described After disconnecting the pipe from the cover remove the two screws...

Page 377: ...lling 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 Fit the cover 2 RS 660 Tuono 660 Cooling system COOL SYS 377 ...

Page 378: ... 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 See also Capacities Cooling system RS 660 Tuono 660 COOL SYS 378 ...

Page 379: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 380: ...o remove the light switches it is necessary to first remove the entire front part of the motorcycle in order to allow the instrument cluster support to be opened in order to access the various connectors Then proceed as described REMOVAL Left 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 and then the two s...

Page 381: ...ector 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 Using compressed air blow at the point indicated to facilitate the removal of the grip 7 RS 660 Tuono 660 Bodywork BODYW 381 ...

Page 382: ...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 Bodywork RS 660 Tuono 660 BODYW 382 ...

Page 383: ...he two screws 2 fastening the right support to the frame Move the right instrument cluster sup port to access the internal part and to be able to remove the clamp 3 that locks the left light switch wiring to the other ones inside After unscrewing the screw remove the metal cable clamp 4 from the right instrument cluster support Remove the right instrument cluster support RS 660 Tuono 660 Bodywork ...

Page 384: ...pletely 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 Remove the rubber clamps 9 to re lease the wiring Bodywork RS 660 Tuono 660 BODYW 384 ...

Page 385: ...ttle 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 RS 660 Tuono 660 Bodywork BODYW 385 ...

Page 386: ...proceeding with the removal it is necessary to disconnect the connectors from the fixed con nectors on the instrument cluster support Then proceed as described THE FOLLOWING OPERATIONS REFER TO A SINGLE REAR VIEW MIRROR BUT APPLY TO BOTH Remove the two rear view mirror lock nuts Remove the rear view mirror and if ap plicable slide the arrow wiring off the fairing Bodywork RS 660 Tuono 660 BODYW 38...

Page 387: ...hen proceed as described After unscrewing the two screws 1 fastening the cover 2 remove it Disconnect the connector 3 from the instrument cluster Lift the instrument cluster 4 sufficient ly to allow the rubber blocks to be re moved from the slotted holes Undo the four screws 5 RS 660 Tuono 660 Bodywork BODYW 387 ...

Page 388: ...ght unit first remove the side fairings the internal covers and the internal fair ings Then proceed as described Remove the two screws 1 fastening the lower front closure 2 Remove the two screws from the lower front closure 2 Remove the nuts 3 fastening the rear view mirrors Bodywork RS 660 Tuono 660 BODYW 388 ...

Page 389: ...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 Remove the eight screws 7 fastening the light unit to the front fairing 8 RS 660 Tuono 660 Bodywork BODYW 389 ...

Page 390: ...d 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 Slide off the top fairing 2 and remove it Bodywork RS 660 Tuono 660 BODYW 390 ...

Page 391: ...fairing and the left side tail fairing Then proceed as described Unhook the cable 1 from the lock block 2 Remove the fork spring 3 Remove the ignition switch assembly 4 downwards and collect the cable support plate 5 Remove the two fixing screws 6 of the lock coupling plate RS 660 Tuono 660 Bodywork BODYW 391 ...

Page 392: ...HE LOWER STEERING YOKE CLOSURE To remove the lower steering yoke clo sure remove the central screw 1 complete with T bushing 2 Remove the two side fixing screws 3 and the corresponding washers 4 Collect the spacer 5 present on the right hand side Bodywork RS 660 Tuono 660 BODYW 392 ...

Page 393: ...e 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 Then proceed as described Disconnect the tail light unit connector 1 Remove the two side fastening screws 2 of the tail light unit RS 660 Tuono 660 Bodywork BODYW 393 ...

Page 394: ... its correct po sitioning which must be restored during the refitting phase Remove the rear light assembly 4 License plate light To remove the license plate light proceed as fol lows Unscrew the screw 1 and remove the closure 2 of the license plate holder Disconnect the license plate light con nector 3 Bodywork RS 660 Tuono 660 BODYW 394 ...

Page 395: ...e side panels it is necessary to first remove the saddles Then proceed as descri bed The operations described refer to a side panel but are valid for both Remove the upper fastener screw 1 Remove the lower fastener screw 2 Move the front part A to the outside then by moving the side panel back wards B it is possible to release it C RS 660 Tuono 660 Bodywork BODYW 395 ...

Page 396: ...cle 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 Remove the internal cover 2 Remove the two internal screws 3 Bodywork RS 660 Tuono 660 BODYW 396 ...

Page 397: ... 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 RS 660 Tuono 660 Bodywork BODYW 397 ...

Page 398: ... the upper screws 9 Separate the two parts that make up the side fairing Fairing mounting panels To remove the under fairings the side fairings must first be removed Then proceed as descri bed RIGHT SIDE Release the vent pipe 2 of the expan sion tank from the cable grommet 1 Bodywork RS 660 Tuono 660 BODYW 398 ...

Page 399: ...n 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 Remove the inner fairing 5 LEFT SIDE Remove the clamp 1 RS 660 Tuono 660 Bodywork BODYW 399 ...

Page 400: ...uts 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 Remove the three screws 7 fastening the inner fairing Bodywork RS 660 Tuono 660 BODYW 400 ...

Page 401: ...r 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 Remove the two side screws 3 com plete with T bushings RS 660 Tuono 660 Bodywork BODYW 401 ...

Page 402: ...ng 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 Remove the two mudguard fixing screws Remove the mudguard Bodywork RS 660 Tuono 660 BODYW 402 ...

Page 403: ...oving the fairing lug disconnect the wiring harness 3 of the side stand sensor from the cable grommets 2 Remove the vent pipe 4 from the ex pansion tank and remove the fairing lug Fuel tank To disassemble the fuel tank remove the rider seat and then proceed as described Unscrew the two screws 1 fastening the front cover 2 of the tank RS 660 Tuono 660 Bodywork BODYW 403 ...

Page 404: ...o front screws 3 and the bushes 4 Undo and remove the rear screw 5 and the bushing 6 Lift the tank slightly just enough to gain access to the vent pipes Remove the clip 7 release the metal clamp 8 and disconnect the vent pipes 9 Bodywork RS 660 Tuono 660 BODYW 404 ...

Page 405: ... tightened correctly Rear wheelhouse To remove the rear wheel arch it is necessary to first remove the battery the fuel tank the saddles the handle the bodies that make up the tail fairing the license plate holder and the side panels Then proceed as described Remove the two fixing screws 1 of the inertia platform 2 with corresponding washers RS 660 Tuono 660 Bodywork BODYW 405 ...

Page 406: ...connector 4 and re move the inertia platform Remove the clamp 5 that binds the main wiring harness to the wheel arch Disconnect the quick shift connector 6 and remove the wiring harness from the rear subframe Disconnect the relays 7 from the holders Bodywork RS 660 Tuono 660 BODYW 406 ...

Page 407: ...emove the protective cover 9 of the main relay Disconnect the main relay 10 from the holders Release the connector 11 from the cable grommet Disconnect the corrugated pipe 12 from the two cable grommets RS 660 Tuono 660 Bodywork BODYW 407 ...

Page 408: ... 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 Bodywork RS 660 Tuono 660 BODYW 408 ...

Page 409: ...r screws 17 fastening the passenger pedals supports to re move them Remove the four screws 18 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 RS 660 Tuono 660 Bodywork BODYW 409 ...

Page 410: ...he 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 Unhook the cable guide 2 connected to the brake hose from the rear part of the mudguard Bodywork RS 660 Tuono 660 BODYW 410 ...

Page 411: ...erations 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 RS 660 Tuono 660 Bodywork BODYW 411 ...

Page 412: ...ng care to collect the T bushes 3 in cor respondence with the three upper fix ing points Instrument cluster cover To remove the instrument panel cover after removing the top ring remove the two fixing screws of the instrument panel cover Remove the instrument panel cover Bodywork RS 660 Tuono 660 BODYW 412 ...

Page 413: ...rument panel Then proceed as described Remove the seven screws 1 fasten ing the left side instrument panel sup port Separate the left part 2 of the support Disconnect the connector 3 for con necting the left arrow only for the American market and then remove the left instrument support Remove the two screws 4 fastening the right side instrument panel support RS 660 Tuono 660 Bodywork BODYW 413 ...

Page 414: ...connector 7 for con necting the right arrow only for the American market and then remove the right instrument support Battery Ensure that the ignition switch is turned to OFF Remove the passenger and rider sad dles Unscrew the two screws 1 and re move the document compartment 2 Bodywork RS 660 Tuono 660 BODYW 414 ...

Page 415: ...ry away on a level surface in a cool and dry place Refit the rider saddle CHECK THAT THE CABLE TERMINALS AND BATTERY LEADS ARE IN GOOD CONDITION NOT CORRODED OR COVERED BY DEPOSITS COVERED BY NEUTRAL GREASE OR PETROLEUM JELLY CAUTION UPON REFITTING CONNECT THE LEAD TO THE POSITIVE TERMINAL FIRST AND AFTER WARDS THE LEAD TO THE NEGATIVE TERMINAL Tail guard To remove the parts that make up the tail ...

Page 416: ... 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 Bodywork RS 660 Tuono 660 BODYW 416 ...

Page 417: ...ble 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 Remove the cover 2 from the rear to allow it to be detached from the ex haust terminal at the points indicated RS 660 Tuono 660 Bodywork BODYW 417 ...

Page 418: ...h the right rider footpeg sup port paying attention not to drop the spacer on the left side of the vehicle located between the footpeg support and the swingarm Remove the front fixing screw 5 pay ing attention to collect the washer and the bushing Remove the cover 6 from the rear to allow it to be detached from the ex haust terminal at the points indicated MOVE THE RIGHT RIDER FOOTPEG SUPPORT OUTW...

Page 419: ...utch 84 163 168 169 171 175 177 181 Connecting rods 188 191 Countershaft 187 225 Crankcase 222 223 225 Crankshaft 186 222 Cylinder 194 195 219 D Desmodromic drum 139 Drive chain 19 307 E Electrical system 7 19 90 Engine oil 58 Exhaust 329 F Fairings 396 Filter box Fork 240 241 246 248 Forks 139 Front wheel 274 Fuel 403 Fuses 121 H Handlebar 236 Head cover 193 221 Headlight 85 388 390 I Identificat...

Page 420: ... Primary shaft 131 138 R Radiator 371 Rear wheel 282 Recommended products 56 S Scheduled maintenance 55 Secondary shaft 133 139 Shock absorber Shock absorbers 267 Side fairings 396 Side stand 326 Spark plug 57 Stand 325 326 Starter motor 145 146 150 T Tank 374 403 Throttle body 62 Transmission 18 U Use W Water pump 366 Wiring diagram 117 ...

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