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APRILIA TUAREG 660, Service Station Manual

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APRILIA TUAREG 660 Service Station Manual Download Page 238

•

Suitably protect the swingarm to pre-

vent it from coming into contact with the

brake fluid when connecting the brake

line.

•

Insert the special screw complete with

new washers fixing the brake line and

tighten it to the prescribed torque.

•

Connect the ABS sensor wiring to the

two cable glands.

•

Insert the ABS sensor in its seat and

secure it by tightening the screw to the

prescribed torque.

•

Fill the rear brake system checking its

level and restore the correct position-

ing of the wiring harness near the

breather screw, blocking it with the pro-

tection cap as indicated.

•

After reassembling the rear wheel, check the distance between the tone wheel and the ABS

sensor.

Characteristic

Distance between tone wheel and the rear sensor

0.5 - 2.00 mm (0.020 - 0.079 in)

Braking system

TUAREG 660

BRAK SYS - 238

Summary of Contents for TUAREG 660

Page 1: ...SERVICE STATION MANUAL 2Q000524 TUAREG 660 ...

Page 2: ...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 beforehan...

Page 3: ...nd 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 and ...

Page 4: ......

Page 5: ... CHARACTERISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE 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: ...le and assembly of the accompanying components Remove the protective cardboard box by pulling it out from above Position a hoist on the front of the vehicle and connect it to the handlebar using straps TUAREG 660 Pre delivery PRE DE 7 ...

Page 8: ...four M10 screws 2 per calliper From the left side of the vehicle un screw the front wheel pin and remove it the two safety screws of the front wheel pin on the clamp of the left stan chion are already loosened Remove the front wheel from the box complete with spacers from both sides and install it on the vehicle by inserting the wheel pin and fixing it at a torque of 65 Nm 47 9 lbf ft Pre delivery...

Page 9: ...ection present be tween the pads inside the brake callip ers Fit the two front brake callipers and tighten the four M10 screws to a torque of 50 Nm 36 9 lbf ft Lower the vehicle and remove the hoist with its lifting straps previously posi tioned on the handlebar TUAREG 660 Pre delivery PRE DE 9 ...

Page 10: ...ollowing operations refer to one handg uard but are valid for both Position the handlebar anti vibration weight and the handguards Using the appropriate fixing screw complete with T bush fasten everything in place Then insert the fixing screw of the handguard to the mount Tighten both screws to a torque of 4 Nm 2 95 lbf ft Pre delivery TUAREG 660 PRE DE 10 ...

Page 11: ...ht ening it to a torque of 50 Nm 36 87 lbf ft Insert the rear view mirror complete with protective rubber and lock nut on the mount Adjust the angle of the rear view mirror and tighten the lock nut To install the right rear view mirror in sert the threaded base complete with spacer on the U bolt of the brake mas ter cylinder tightening it to a torque of 50 Nm 36 87 lbf ft TUAREG 660 Pre delivery P...

Page 12: ...mets paying atten tion to recover the bushes positioned on the support Insert the rubber grommets on the windscreen Position the windscreen on the sup port insert the four screws complete with bushings and making sure that the bushings are correctly inserted in the support tighten the windscreen screws to a torque of 9 Nm 6 63 lbf ft Aesthetic inspection Paintwork Fitting of Plastic Parts Scratche...

Page 13: ...trument panel 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 able upgrades and details regarding the operation CAUTION TO ENSURE MAXIMUM PERFORMANCE THE ...

Page 14: ...ttery 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 the touch Allow the battery to cool before resuming charging After recharging the battery leave it to stand for 1 hour before pressing the TEST button on the BATTERY CAPACITY INDICATOR If...

Page 15: ...TTERY DOES NOT CONTAIN HARMFUL POLLUTANTS CORROSIVE ACIDS OR TOXIC HEAVY METALS IF APPLICABLE TRADITIONAL BATTERY ACTIVATION PRO CEDURE Place the battery on a flat surface Remove the cell s protective sticker Take the acid container Remove the cap 1 of the container 2 Place the container upside down per pendicularly above the battery align ing the outlets with the battery cells Apply pressure to t...

Page 16: ...Y CHARGER WITH 1 2 AMPERE CHARGING TIME 5 10 HOURS OR 5 AMPERE CHARGING TIME 1 HOUR Levels check Hydraulic braking system fluid level Clutch system fluid level Engine coolant level Engine oil level Road test Cold start Instrument panel operation Response to throttle control Stability when accelerating and braking Front and rear brake efficiency Front and rear suspension efficiency Abnormal noise S...

Page 17: ...se 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 PRESSURE WITH TYRES AT AMBIENT TEMPERATURE TUAREG 660 Pre delivery PRE DE 17 ...

Page 18: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 19: ...NOT 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...

Page 20: ...H OF 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 PARTICUL...

Page 21: ...umable 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 th...

Page 22: ...ULD LOOSEN AND COME OFF BLOCKING 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 in is essential to ensure the durability of the vehicle During the first 1 000 Km 621 mi observe the following rules to ensure the reliability and performance of the vehicle throughout its lifetime Avoid full t...

Page 23: ...L NUMBER LOCATION These numbers are necessary for vehicle registration NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW IN PAR TICULAR MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY This number consists of numbers and letters as in the example shown below ZD4XBA000YSXXXXXX KEY ZD4 WMI World Manufacturer Identifier code XB model A00 Europe UA0 USA 0 digit free Y ...

Page 24: ...ed 1400 100 rpm Engine revs at maximum speed 9250 100 rpm Clutch Multi plate wet clutch with mechanical control lever on left side of the handlebar Anti juddering and slipper clutch systems Starting Electric Timing Morse chain on intake and exhaust camshafts bucket tappets and valve clearance adjustment with calibrated pads Lubrication system Wet sump with pump Oil pump Trochoidal pump Oil filter ...

Page 25: ...uel tank reserve capacity 2 7 l 0 59 UK gal 0 71 US gal Engine oil oil change and oil filter replacement 2300 cc in 140 35 cu in Coolant 2 0 2 l 0 43 0 04 UK gal 0 52 0 05 US gal Seats 2 Maximum weight limit 414 kg 912 71 lb Drive chain DRIVE CHAIN Specification Desc Quantity Type Regina 120 links With sealed master link Model 520 ZRA Electrical system ELECTRICAL SYSTEM Specification Desc Quantity...

Page 26: ...er Progressive linkage with piggy back Adjustable spring pre load hydraulic compression and rebound damping Rear stroke 106 5 mm 4 19 in FRAME DIMENSIONS Specification Desc Quantity Size A 559 1 mm 22 01 in measurements refer to the bare chassis Size B 456 9 mm 17 98 in measurements refer to the bare chassis Angle C 26 7 0 25 measurements refer to the naked frame Brakes BRAKES Specification Desc Q...

Page 27: ...T THE INFLATION PRESSURE INDICATED IN EVERY DRIVING ROUTE CONDITION FAILURE TO COMPLY WITH THIS PRESCRIPTION CAN CAUSE SERIOUS DAMAGE TO THE WHEELS AND TO THE VEHICLE IN GENERAL IN PARTICULAR RIDING WITH INFLATION PRESSURES LOWER THAN THOSE PRESCRIBED IS HIGHLY UNRECOMMENDED Supply FUEL SYSTEM Specification Desc Quantity Fuel Unleaded gasoline E10 95 R O N Tightening Torques If the following table...

Page 28: ...ft 2 Nm 1 47 lb ft 3 Nm 2 21 lbf ft CAUTION THE SCREWS WITH THREAD LOCK SEALANT PRE IMPREGNATED MUST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED 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 Characteristics TUAREG 660 CHAR 28 ...

Page 29: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 30: ...engine timing wrench 021043Y Camshaft timing pin 020851Y Camshaft timing pin 9100896 Clutch bell stopper 021036Y Flywheel side crankshaft locking tool 021037Y Water pump seal insertion tool 021038Y Crankshaft support U bolt Special tools TUAREG 660 S TOOLS 30 ...

Page 31: ...Pick up distance template 021040Y Transmission shaft oil seal press fit punch on front sprocket side 021041Y Engine fixing bracket to mount 021042Y Oil seal and clutch shaft bearing and gear shaft punch 020980Y Piston assembly ring TUAREG 660 Special tools S TOOLS 31 ...

Page 32: ...40179 Valve fitting removal support 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020713Y Flywheel puller tool 020376Y Adaptor handle 020655Y Adaptor 62x68 mm Special tools TUAREG 660 S TOOLS 32 ...

Page 33: ...5 mm punch 020414Y 28 mm punch 020712Y Handle for removing the flywheel cover AP8140190 Steering tightening tool AP8140189 Tool for mounting the oil seal for holes with diam 43 mm 1 69 in AP8140149 Guard for assembly operations TUAREG 660 Special tools S TOOLS 33 ...

Page 34: ...es code Description AP8140146 Weight 020888Y Pre load tube clamp AP8140150 Bored shaft for bleeding plunger air 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles Special tools TUAREG 660 S TOOLS 34 ...

Page 35: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 36: ...24 9 12 months 24 months Rear shock absorber bearings linkage systems 4 I I I I Engine oil filler plug O ring I I I I I I I Flywheel cover cap O Ring I I Fork plug O ring I Motorcycle set up I I I I I Spark plug R R Drive chain 2 4 I L I L I L I L I L I I Clutch cable 4 L L L L L L L Front sprocket rear sprocket Chain slider chain ten sioner roller I I I I Steering bearings and steering play I I I...

Page 37: ...DED PRODUCTS Product Description Specifications Engine oil 10W 50 Synthetic based lubricant for high per formance four stroke engines SAE 10W 50 API SL JASO MA2 Lithium based grease Lithium calcium soap based grease colour black contains EP Extreme Pressure additives excellent water re pellent properties Anti freeze liquid ready to use colour red Ethylene glycol antifreeze liquid with or ganic inh...

Page 38: ...ARM 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 wh...

Page 39: ... 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 For the replacement of the engine oil the sump guard must be removed beforehand Then pro ceed as described Place a container with suitable capaci ty under the drainage plug Unscrew and rem...

Page 40: ...ts 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...

Page 41: ...ing 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 To remove the air filter the fuel tank upper cover must be removed beforehand Then proceed as described Working from both sides remove the four fixing screws of the filter box cover Remove the filter ho...

Page 42: ...irst be removed Then proceed as described Remove the fixing screw 1 of the air pressure sensor and disconnect the connector 2 from the sensor itself After disconnecting the connectors 3 from the ECU free the VEHICLE wiring harness and the rear stop switch wiring harness 4 from the cable guide Remove the ECU 5 Maintenance TUAREG 660 MAIN 42 ...

Page 43: ... tank breather pipe Remove the side fixing screw 7 of the ECU support Disconnect the fuel tank breather pipe 8 from the cable grommets on the ECU support Disconnect the pick up connector sup port 9 from the ECU support Remove the fastening screw of the SAS valve support TUAREG 660 Maintenance MAIN 43 ...

Page 44: ... the cables connected to the filter box support Disconnect the two pick up generator sensor wiring harnesses 10 and the ABS modulator wiring harness 11 from the cable grommet on the ECU support Remove the ECU support Disconnect the connector of the fuel pipe and remove it Maintenance TUAREG 660 MAIN 44 ...

Page 45: ...o facilitate the re moval of the throttle body Remove the clamp and disconnect the pipe from the purge valve CAUTION DURING REASSEMBLY USE A NEW METAL CLAMP Remove the two metal clamps secur ing the throttle body to the rubber mani folds Disconnect the throttle body CAUTION USE NEW METALLIC CLAMPS DURING REASSEMBLY TUAREG 660 Maintenance MAIN 45 ...

Page 46: ...he throttle body as indicated to help removal and extract it Throttle body installation To install the throttle body carry out the procedures described in paragraph Throttle body removal in reverse order paying attention to use new metal clamps where indicated Air filter housing Maintenance TUAREG 660 MAIN 46 ...

Page 47: ...d then proceed as described Disconnect the tank breather pipes from the filter box Disconnect the intake air temperature sensor connector Undo and remove the two upper fixing screws of the ECU support Remove the metal clamp and discon nect the breather pipe TUAREG 660 Maintenance MAIN 47 ...

Page 48: ...move the three side fix ing screws Partially raise the filter box remove the metal clamp and disconnect the breather pipe Remove the filter box To remove the air filter inside the filter box carry out the procedure described in paragraph air filter in the maintenance chapter See also Air filter Maintenance TUAREG 660 MAIN 48 ...

Page 49: ... THICKNESS UPWARDS Pad thickness for adjusting valve clearance correctly 1 75 mm 0 0689 in 1 77 mm 0 0697 in 1 80 mm 0 0709 in 1 82 mm 0 0716 in 1 85 mm 0 0728 in 1 87 mm 0 0736 in 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 TUAREG 660 Maintenance MAIN 49 ...

Page 50: ...7 mm 0 0933 in 2 4 mm 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 11...

Page 51: ...de of the vehicle under the steering head stock that the fluid level in the expan sion tank is between the MIN mini mum and MAX maximum marks WARNING CARRY OUT THE CHECK AND TOP UP THE REFRIGER ANT LIQUID WITH THE ENGINE SWITCHED OFF AN COLD Top up Remove the expansion tank cap Top up with the recommended liquid until reaching an intermediate level be tween the MIN bar and the MAX bar of the expan...

Page 52: ...r the disc have to be replaced check the brake fluid and top up if necessary Top up RISK OF BRAKE FLUID SPILLING DO NOT OPERATE THE BRAKE LEVER IF THE BRAKE FLUID RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESER VOIR OPEN ONLY FOR THE TIME NEEDED TO...

Page 53: ...ING 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 Rear braking system Unscrew the cap 5 and remove to gether with the gasket 6 Top up the reservoir 7 with...

Page 54: ...cover Unscrew the lock nut 4 partially Turn the pin 5 checking with a thick ness gauge the correct play in the in dicated point 1 5 mm 0 05 in Finish the adjustment by tightening the lock nut Regolazione leva frizione Adjust the clutch lever if the engine stalls or if the vehicle creeps forward when the lever is pulled or if the clutch slips causing a lag in acceleration rel ative to increases in ...

Page 55: ...s 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 s...

Page 56: ...ust the vertical alignment of the low beam headlight beam NOTE CHECK THAT THE VERTICAL ALIGNMENT OF THE BEAM IS CORRECT HIGH BEAM HEADLIGHT From under the light using a Phillips head screw driver act on the adjuster 3 at the point indicated Turn the screwdriver clockwise to raise the beam Turn the screwdriver anticlockwise to lower the beam This adjuster screw may be used to adjust the ver tical a...

Page 57: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 58: ...dge clip Sheet Ø10mm 1 x Edge clip Sheet Ø20mm 1 x Edge clip Sheet Ø10mm 5 x AMP connector support 1 x Front ABS sensor support 1 x Rear ABS sensor support 2 x Small cable glands 3 x Large cable glands 11 x Brake line guides 2 x Edge cable guides 1 x Fuel Pump cable guide 5 x Edge clamps 1 x Cable glands 1 x Int support Rear Stop Small parts and mountings 3 x large black clamps 290x4 mm 9 x Small ...

Page 59: ...obe 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 connection of Fan connectors 1 and 2 Check the starter relay connection with the main wiring harness red 4 way connector Check correct connection of the starter relay cables and fastening of screws with torque wrench Check the rear stop...

Page 60: ... 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 USB PRE ASSEMBLY Insert the USB port on the left side sup port of the instrument cluster making sure that the slot in the cap is facing upwards Electrical system ...

Page 61: ... temperature sen sor on the right side support of the instrument cluster TABLE C PRE ASSEMBLY OF THE EDGE FIX ING TIES ON THE INSTRUMENT CLUSTER SUPPORT Position the three edge ties as indica ted on the right instrument cluster sup port TUAREG 660 Electrical system ELE SYS 61 ...

Page 62: ...e guide in the point in dicated on the central instrument clus ter support TABLE E HEADLIGHT PRE ASSEMBLY Insert the connector mount on the headlight TABLE E1 HEADLIGHT PRE ASSEMBLY Connect the headlight connector to the mount as indicated Electrical system TUAREG 660 ELE SYS 62 ...

Page 63: ...ION BLOCK PRE ASSEMBLY Secure the immobilizer wiring harness with a tie as indicated TABLE G RIGHT SWITCH CLUSTER PRE AS SEMBLY Position the right switch cluster as in dicated TUAREG 660 Electrical system ELE SYS 63 ...

Page 64: ... Position the right switch cluster as in dicated TABLE H1 LEFT SWITCH CLUSTER PRE AS SEMBLY Always check that the wiring harness es of the switch clusters are not pinched when fastening the clutch lev er Electrical system TUAREG 660 ELE SYS 64 ...

Page 65: ...s in dicated secure the switch using the nut so as to obtain a 4 mm protrusion of the thread as indicated TABLE J FRONT ABS SENSOR PRE ASSEM BLY After connecting the ABS sensor to the right stanchion arrange the wiring as shown and secure it using the special metal plate TUAREG 660 Electrical system ELE SYS 65 ...

Page 66: ...ring harness of the front ABS sensor to the front brake line us ing five cable guides at the points shown FIGURE K1 FRONT ABS SENSOR Position the connector socket on the bracket at the point indicated Electrical system TUAREG 660 ELE SYS 66 ...

Page 67: ...oned previously Using a cable clamp secure the front ABS sensor wiring harness to the front brake line at the point indicated TABLE L HANDLEBAR AND IGNITION BLOCK AREA CABLE ROUTING Using rubber cable clamps secure the handlebar wiring harnesses as shown TUAREG 660 Electrical system ELE SYS 67 ...

Page 68: ...luster to the right of the steering headstock TABLE L2 HANDLEBAR AND IGNITION BLOCK AREA CABLE ROUTING Route the clutch switch and left switch cluster wiring harness behind the igni tion block and position it to the right of the steering headstock along with the previously positioned harnesses Electrical system TUAREG 660 ELE SYS 68 ...

Page 69: ... right of the steering headstock along with the pre viously positioned harnesses TABLE M ROUTING THE CABLES IN THE IN STRUMENT PANEL SUPPORT AREA Position the right instrument panel sup port taking care to insert all the han dlebar wiring and the branch of the main wiring harness TUAREG 660 Electrical system ELE SYS 69 ...

Page 70: ...ing and antenna wiring Once they have all been pulled fasten the clamp highligh ted by the arrow in the photo Once fastened let go of the cables and po sition them for the next step TABLE M2 ROUTING THE CABLES IN THE INSTRUMENT PANEL SUPPORT AREA Keep the wiring harness of the left switch cluster 1 as far to the left as possible Position the rest of the cables as in the photo and fasten the other ...

Page 71: ...h connector 1 positioning it in the indicated point and insert the wiring harness on the cable guide TABLE N1 INSTRUMENT PANEL AREA CON NECTORS CONNECTION SEQUENCE Connect the USB port connector 2 by positioning it in the indicated connector holder TUAREG 660 Electrical system ELE SYS 71 ...

Page 72: ...ning it in the indicated connector holder Connect the switch cluster connector 4 and position it under the connector 3 TABLE N3 INSTRUMENT PANEL AREA CON NECTORS CONNECTION SEQUENCE Connect the right switch cluster con nector 5 by positioning it in the indi cated connector holder Electrical system TUAREG 660 ELE SYS 72 ...

Page 73: ...grips and anti theft LED connector must be positioned in the area highlighted by the circle and all passed through the indicated cable gland TABLE N5 INSTRUMENT PANEL AREA CON NECTORS CONNECTION SEQUENCE Connect the throttle control connector 6 and position it where indicated TUAREG 660 Electrical system ELE SYS 73 ...

Page 74: ...the antenna connector TABLE N7 INSTRUMENT PANEL AREA CON NECTORS CONNECTION SEQUENCE After having made all the connections and fastened everything the curves of the cables that enter the instrument panel support must be as in the photo If they are too long they hinder the movement of the handlebar to the right Electrical system TUAREG 660 ELE SYS 74 ...

Page 75: ...witch using the special support and secure the wiring harness by means of the cable guide at the point indicated TABLE B SIDE STAND SENSOR PRE AS SEMBLY Fix the side stand sensor to the support paying attention to the correct position ing TUAREG 660 Electrical system ELE SYS 75 ...

Page 76: ...SEMBLY The small fan should have the cables facing down and the large fan facing up TABLE C1 RADIATOR FAN PRE ASSEMBLY Use a clamp at the point indicated to hold the wiring harness in place Electrical system TUAREG 660 ELE SYS 76 ...

Page 77: ...TART ER CABLES ON THE FRAME Position the three cable guides on the frame as shown TABLE D1 PRE ASSEMBLY OF THE CABLE GUIDES FOR THE PASSAGE OF THE START ER CABLES ON THE FRAME Position the two cable guides on the frame as shown TUAREG 660 Electrical system ELE SYS 77 ...

Page 78: ... GUIDE ON THE TANK Fix the cable guide to the tank as shown TABLE F PRE ASSEMBLY OF THE FUEL LEV EL PROBE ON THE TANK The fuel level sensor wiring harness output must face the rear of the vehicle Electrical system TUAREG 660 ELE SYS 78 ...

Page 79: ...dge cable guides in the indicated points on the rear part of the ECU support TABLE H GEAR SENSOR CABLE PASSAGE The cable must pass adherent to the base of the engine as indicated and re main below the starter motor fixing screw TUAREG 660 Electrical system ELE SYS 79 ...

Page 80: ...E PASSAGE The wiring harness must pass between the rubber tube and the head of the en gine as in the photo TABLE H2 GEAR SENSOR CABLE PASSAGE The wiring harness must pass as in the photo Electrical system TUAREG 660 ELE SYS 80 ...

Page 81: ...hown in the photo TABLE J CONNECTION OF THROTTLE VALVE ENGINE WATER TEMPERATURE SECONDARY AIR VALVE Connect the connector of the throttle valve 1 of the engine water temper ature 2 and of the secondary air valve 3 making sure they are correctly in serted TUAREG 660 Electrical system ELE SYS 81 ...

Page 82: ...ect the connectors of the coils 1 of the injectors 2 and of the map sen sor 3 making sure they are correctly inserted TABLE K1 ENGINE HEAD AREA CONNEC TIONS Connect the ground cable at the point indicated Electrical system TUAREG 660 ELE SYS 82 ...

Page 83: ...e initial position of the connector coupling lever must be as indicated in the figures TABLE L1 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 TUAREG 660 Electrical system ELE SYS 83 ...

Page 84: ...x 12 mm In this case repeat the operation de scribed in TABLES L1 L2 We recommend creating a template in order to ensure that the connector is inserted correctly TABLE L4 PROCEDURE FOR THE CORRECT FITTING OF THE ABS CONTROL UNIT CON NECTOR It is possible to check the correct in sertion of the connector on the motor cycle by verifying that the yellow line is Flush with the connector TABLE M OIL TEM...

Page 85: ...LE M1 OIL TEMPERATURE SENSOR AND OIL PRESSURE SENSOR The wiring harness must be routed as indicated TABLE M2 OIL TEMPERATURE SENSOR AND OIL PRESSURE SENSOR Position a large clamp about 25 mm from the Y of the horn output TUAREG 660 Electrical system ELE SYS 85 ...

Page 86: ...TABLE N HORN CONNECTION Connect the horn connectors as shown TABLE O MAIN WIRING HARNESS The main wiring harness must be posi tioned as indicated Electrical system TUAREG 660 ELE SYS 86 ...

Page 87: ... of the rear brake switch is correctly hooked and objectified to the support It must be positioned approximately 10 mm from the cable guide 2 TABLE P FALL SENSOR After fixing the fall sensor 1 connect the connector 2 TUAREG 660 Electrical system ELE SYS 87 ...

Page 88: ...nnector is correctly objectified on the ABS control unit support TABLE Q ECU Always check the correct connection of the ECU Pull the grey levers that should not move in the direction of the arrow with your finger Electrical system TUAREG 660 ELE SYS 88 ...

Page 89: ...ectly tightened and check the correct tightening torque Check the correct passage of the start er motor cable which must be inserted in the cable guide 3 as in the photo TABLE S LEFT LAMBDA PROBE After having correctly fixed the left lambda probe route the wiring harness between the engine frame and behind the cooling hose as indicated TUAREG 660 Electrical system ELE SYS 89 ...

Page 90: ...ft lambda connector is correctly connected and objectified as indicated TABLE S2 RIGHT LAMBDA PROBE After connecting the right lambda probe pass the wiring harness be tween the engine and the engine mount Electrical system TUAREG 660 ELE SYS 90 ...

Page 91: ...ng harness of the left electric fan 1 must pass externally to the en gine mount as indicated and the con nector 2 objectified in the indicated point Secure the wiring harness using an edge clamp 3 Using a clamp 4 secure the wiring harness paying attention to obtain a distance greater than 20 mm at the point indicated TUAREG 660 Electrical system ELE SYS 91 ...

Page 92: ...ternally between the frame and the engine After checking the correct connection of the connector insert it in the special housing on the left side of the frame TABLE T2 RIGHT ELECTRIC FAN Using a clamp secure the wiring har ness and the connector Electrical system TUAREG 660 ELE SYS 92 ...

Page 93: ... nectors to the voltage regulator TABLE V FILTER BOX AIR TEMPERATURE SENSOR Route the air temperature sensor wir ing harness behind the breather pipe and inside the slot on the filter box Check that the filter box air tempera ture connector is correctly connected TUAREG 660 Electrical system ELE SYS 93 ...

Page 94: ...ame by means of a clamp TABLE X FUEL LEVEL PROBE Correctly connect the connector of the fuel level probe and mark it on the ap propriate support Using two clamps secure the wiring harness together with the right lambda probe and auxiliary lights provision wir ing harnesses Electrical system TUAREG 660 ELE SYS 94 ...

Page 95: ...UEL LEVEL PROBE Check that the fuel pump connector is correctly connected TABLE Y1 FUEL LEVEL PROBE Check that the fuel pump wiring har ness is inserted in the cable guide TUAREG 660 Electrical system ELE SYS 95 ...

Page 96: ... edge clamp 1 and two edge cable grommets 2 on the under seat compartment TABLE B PRE ASSEMBLY OF TURN INDICA TORS ON LICENSE PLATE HOLDER Connect the turn indicators to the li cense plate holder passing the cables as indicated Electrical system TUAREG 660 ELE SYS 96 ...

Page 97: ...nnect the taillight to the centre tail fairing TABLE D STARTER RELAY AREA CABLE PASSAGE ON LEFT SIDE OF SEAT POST Arrange the cables on the left side and insert them in the indicated cable glands TUAREG 660 Electrical system ELE SYS 97 ...

Page 98: ...l wiring harnesses TABLE D2 STARTER RELAY AREA CABLE PASSAGE ON LEFT SIDE OF SEAT POST Check the correct tightening torque of the starter relay screws TABLE D3 STARTER RELAY AREA CABLE PASSAGE ON LEFT SIDE OF SEAT POST Check the correct connection of the starter relay connector Electrical system TUAREG 660 ELE SYS 98 ...

Page 99: ...TABLE E SIDE STAND CABLE ROUTE The side stand sensor harness must pass as shown TABLE E1 SIDE STAND CABLE ROUTE The side stand sensor harness must pass as shown TUAREG 660 Electrical system ELE SYS 99 ...

Page 100: ... sensor harness must pass through the indicated cable glands TABLE F TAIL LIGHTS AND TURN INDICA TORS Secure the branch of the main wiring harness for the rear connections using a tie at the point indicated Electrical system TUAREG 660 ELE SYS 100 ...

Page 101: ...t and in serted in the cable glands The red taping must coincide with the cable glands TABLE F2 TAIL LIGHTS AND TURN INDICA TORS Correctly connect the connectors of the taillight unit and the turn indicators and then proceed with the installation of the license plate holder TUAREG 660 Electrical system ELE SYS 101 ...

Page 102: ... the RED mark ing on the cable The large tie 2 must gather 3 of the 4 branches that exit the duct It must not gather the connector for the fuel pump TABLE G1 RELAY AREA CABLE ROUTING ON RIGHT SIDE Position the grey connector facing to wards the inside of the motorcycle Electrical system TUAREG 660 ELE SYS 102 ...

Page 103: ...out the marking on the wiring harness facing towards the outside of the vehicle TABLE G3 RELAY AREA CABLE ROUTING ON RIGHT SIDE Position the relay with the GREY marking on the wiring harness facing towards the outside of the vehicle TUAREG 660 Electrical system ELE SYS 103 ...

Page 104: ... SIDE Position the connector with cap and rubber grommet on the tab provided on the frame TABLE H FUSE BOXES Arrange the fuse boxes on the wheel arch and secure the wiring harness at the point indicated Electrical system TUAREG 660 ELE SYS 104 ...

Page 105: ... 300 mm from the sensor Secure the wiring harness using the slot in the brake calliper bleeder cap TABLE I1 REAR ABS SENSOR The rear ABS sensor wiring must pass through the cable grommets 1 on the swingarm and fastened to the brake line by means of a cable gland 2 TUAREG 660 Electrical system ELE SYS 105 ...

Page 106: ...gh the cable gland 1 on the swingarm and fastened to the brake line by means of two cable glands 2 TABLE I3 REAR ABS SENSOR The ABS sensor wiring harness must be fastened to the main wiring harness duct with a tie at the point indicated Electrical system TUAREG 660 ELE SYS 106 ...

Page 107: ...tly connect the rear ABS sensor connector and mark it at the point indi cated TABLE J OBDII CONNECTOR The OBDII connector must be connec ted into the special holder on the bat tery support box TUAREG 660 Electrical system ELE SYS 107 ...

Page 108: ...ambient air temperature sensor 5 Instrument cluster 6 RH Column light switch 7 Starter motor sensor connector 8 Rear brake switch 9 Clutch switch 10 Ignition switch 11 Immobilizer antenna 12 Tail light with integrated license plate light Electrical system TUAREG 660 ELE SYS 108 ...

Page 109: ...7 Voltage regulator 28 Starter motor 29 Main starter relay 30 Main fuse 31 Battery 32 Stand switch 33 Auxiliary fuses 1 1 fuse 34 Bridge on no DRL versions only 35 Fuel pump relay 36 Injection relay 37 Fuel reserve sensor 38 Fuel pump 39 Purge valve 40 GAS R W hand grip 41 Secondary air system 42 Quick Shift switch UP DOWN 43 Neutral gear sensor 44 Lambda cylinder 2 45 Lambda cylinder 1 46 Injecto...

Page 110: ... LED module 63 Low beam LED module 64 DRL 65 Front turn indicator RH 66 Fuel level probe 67 Engine ground point 68 Engine head ground point 69 Diagnostics CAN 2 70 T derating sensor 71 RH LH fog lights optional 72 Fog light relay optional 73 Fall sensor Checks and inspections Immobiliser System not programmed Storing new keys NOTE REGARDLESS OF THE LANGUAGE SET IN THE DASHBOARD FUNCTIONS THE KEY P...

Page 111: ...THE 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...

Page 112: ...number of start ups together with the self discharge are important negative variables as well Regarding these aspects relating to the energy balance of the vehicle it is important to guarantee the correct idle speed especially for those versions with carburettor for which the system does not establish a value For vehicles that have been used for a long time at idle speed a speed close to maximum s...

Page 113: ...GE SYSTEM CONNECTIONS The first useful intervention is the correct coupling of the connectors of the recharge system stator regulator or stator vehicle system and the vehicle system regulator For this check try to separate the connections without operating the retaining devices Also check that the cable terminals are inserted in the connector until the stopper fastener If there are anomalies disco...

Page 114: ...specified check re place the stator ISOLATION OF THE GENERATOR S PHASES Using a multimeter check the ground insulation of each phase R 1 MΩ If the stator and its cable harness are compliant in terms of continuity any short circuit to the ground of one phase will be identified on the three phases If a short circuit to ground is detected repair the wiring harness or replace the stator CONSUMPTION CH...

Page 115: ...ry pole creating thus the conditions of a miliammeter in series with the sys tem load For the versions with immobilizer the load will be pulsed with the deterrent flashing frequency The normal values are comprised between 2 mA with the LED off and 15 mA with the LED on If significantly higher consumption is detected it is necessary to progressively disconnect the con sumers with direct power suppl...

Page 116: ...the dy namic checks PRELIMINARY CHECK OF THE RECHARGE SYSTEM A summary check of the recharge performance can be performed by connecting the multimeter with voltmeter function to the battery poles Observe the battery voltage during standby and then start the engine and progressively accelerate until 3000 rpm If the recharge system is efficient the battery volt age increases progressively until 13 5...

Page 117: ...f the battery voltage or that the regulator s output does not exceed 15 V for any engine rpm If incorrect voltage values are detected replace the voltage regulator For vehicles with the voltage regulator placed far from the battery it is important to check both volt age values during the maximum output of the gen erator the regulator s voltage and the battery voltage Any difference of a few tenths...

Page 118: ...use 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 FREQUENTLY MAY INDICATE A SHORT CIRCUIT OR OVERLOAD CON TACT AN authorised aprilia Dealer To check To avoid an accidental short circuit...

Page 119: ...r relay D 7 5A fuse ECU permanent positive lead E 5A fuse Positive key on power for AMP positive key on power for OBD positive key on power for anti theft system 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 supply ECU power supply fuel pump relay power supply lambda probe power supply injector power sup ply coil power supply s...

Page 120: ...G FITTING CAUTION REMOVING THE 30A FUSE WILL RESET THE DIGITAL CLOCK AND TRIP INFORMATION LOCATION OF THE MAIN FUSE Specification Desc Quantity O 30A fuse Battery charging all vehicle utilities P spare fuse The main fuse is located behind the left hand side fairing of the motorcycle under the rider saddle Control unit ENGINE TONE WHEEL PROGRAMMING PRO CEDURE Using the PADS diagnostic tool per form...

Page 121: ...E THE VEHICLE S SPEED MUST ALWAYS BE 0 km h IN CERTAIN CASES EVEN SMALL VIBRATIONS GENER ATED BY THE ENGINE WITH THE ENGINE IN NEUTRAL POSITION AND THE SIDE STAND EXTENDED OPEN THE INSTRUMENT PANEL DOES NOT DETECT THE VEHICLE S SPEED MAY CAUSE THE PROCEDURE TO FAIL WHICH MEANS IT HAS TO BE REPEATED IN THIS CASE REPEAT THE PROCEDURE WITH THE SIDE STAND CLOSED AND VEHICLE IN NEUTRAL ALWAYS PAYING EX...

Page 122: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 123: ...TUAREG 660 Engine from vehicle ENG VE 123 ...

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

Page 125: ...TUAREG 660 Engine ENG 125 ...

Page 126: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 127: ...the oper ation with the fuel tank removed is the same Proceed as described Disconnect the electrical connector of the fuel pump Disconnect and remove the safety plate of the fuel pipe Disconnect the fuel pipe from the fuel pump Unscrew and remove the ring nut of the fuel pump TUAREG 660 Power supply P SUPP 127 ...

Page 128: ... Remove the fuel pump complete with seal Power supply TUAREG 660 P SUPP 128 ...

Page 129: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 130: ...ebar after removing the handguards proceed as follows Remove the cable guides 1 Undo the four screws 2 and remove the U bolt 3 Unscrew the screw 4 move the han dlebar to the left and remove the throt tle control 5 Suspensions TUAREG 660 SUSP 130 ...

Page 131: ... right switch cluster 7 Unscrew the screws 8 move the han dlebar to the left and remove the brake master cylinder 9 Remove the left hand grip 10 Unscrew the screw 11 move the han dlebar to the right and remove the left switch cluster 12 TUAREG 660 Suspensions SUSP 131 ...

Page 132: ... For the settings of the vehicle set up Each stanchion has an upper nut 1 to adjust the spring pre load An upper adjuster screw 2 on the left stanchion for setting the hydraulic compression damping An upper adjuster screw 3 on the right stanchion for setting the hydraulic re bound damping TO AVOID DAMAGE DO NOT FORCE THE ADJUSTERS BEYOND THE MAXIMUM SETTING POSITION IN EITHER DIRECTION SET BOTH ST...

Page 133: ...fication Desc Quantity Spring pre loading nut 1 from fully closed unscrew 6 mm 0 23 in Hydraulic compression adjustment adjuster screw 2 Unscrew 8 clicks from fully closed Hydraulic rebound adjustment adjuster 3 Unscrew 8 clicks from fully closed Stanchion protrusion A from top yoke excluding cover 1 notches STANDARD ADJUSTMENT RIDER PASSENGER RIDER LUGGAGE RIDER PASSENGER LUGGAGE Specification De...

Page 134: ...oceed as described THE FOLLOWING OPERATIONS REFER TO A STANCHION BUT APPLY TO BOTH IF APPLICABLE Unscrew the fixing screw of the ABS wiring harness plate and remove it Undo the fixing screw of the ABS sen sor and remove it Unscrew the two locking screws of the stanchion on the lower triple tree clamp Unscrew the two locking screws of the stanchion on the upper triple tree clamp Suspensions TUAREG ...

Page 135: ... TO A SINGLE STANCHION BUT APPLY TO BOTH Clamp the fork in a vice with the spe cific protective jaws taking care not to damage them Completely unscrew the cap 1 and lift the stanchion placing a support under it Specific tooling AP8140149 Guard for assembly operations Using the specific tool 2 fixed to the pre load tube compress the spring and insert a wrench on the locking nut 3 of the cap 1 TUARE...

Page 136: ...d operator while compressing the pre load spring again unscrew and remove the cap 1 Extract the hydraulic braking control rod 4 After removing the specific tool for compressing the pre load spring re move the upper plate 5 Remove the pre loading tube 6 Suspensions TUAREG 660 SUSP 136 ...

Page 137: ...O NOT DISPOSE OF OIL IN THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE Disassembling the fork To proceed with the disassembly of the fork pro ceed as described Extract the dust seal 8 from the sleeve Disconnect the snap ring 9 from in side the sleeve TUAREG 660 Suspensions SUSP 137 ...

Page 138: ...r rod from the stanchion Checking the components stanchion Check that the sliding surface is not scratched or scored Any scoring can be removed by sanding with damp sandpaper grain 1 If the scratches are deep replace the stanchion Using a dial gauge check than any bending of the stanchion is below the limit value If it is over the limit replace the stanchion CAUTION A BENT STANCHION SHOULD NEVER B...

Page 139: ...NG OPERATIONS REFER TO A SINGLE STANCHION BUT APPLY TO BOTH To reassemble the fork proceed as follows Insert the dust guard 1 the seeger ring 2 the oil seal 3 the ring 4 the guide bushing 5 and the slider bush ing 6 on the stanchion Using the special protective jaws block the stanchion horizontally in a vice Insert the complete damper rod 7 on the stanchion Insert a new seal washer 8 on the fix in...

Page 140: ...t 2 Insert the dust guard 1 into its hous ing correctly Filling oil NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE STANCHION BUT APPLY TO BOTH Place the sleeve upright in a vice fitted with protection shoes Compress the sleeve in the stanchion Place a support under the stanchion in order to leave it compressed Remove the white spacer of the damp er rod and the locking nut of the fork cap screwed ...

Page 141: ...NS Specific tooling AP8140149 Guard for assembly operations Oil level 90 mm 3 54 in from the stanchion edge without a spring pre load tube spacer and nut 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 577 cm 35 21 cu in for each stanchion Insert the spacer 10 and fully tighten the cap locking ...

Page 142: ...narrower part must be inserted into the spring Position the upper plate 15 on the pre load tube Before positioning the cap adjust the hydraulic regulator screw so that the internal distance is as close as possi ble to 13 mm 0 51 in Position the specific tool to compress the spring and with the help of a sec ond operator after compressing the spring manually screw the cap 16 until in contact with t...

Page 143: ... remove the handlebar complete with grips throttle control light switches clutch lever and front brake master cylinder To carry out this operation after having unscrewed the four screws 1 remove the U bolt 2 Adequately protect the instrument cluster disconnect the handlebar 3 and place it on the front as indicated Remove the fixing bush 4 and the washer 5 TUAREG 660 Suspensions SUSP 143 ...

Page 144: ... clamp Remove the two ties 7 that fasten the wiring harness of the handlebar com ponents to the triple tree clamp Extract the upper triple clamp 8 from the pin Remove the two screws 9 securing the ignition assembly 10 USE A NEW SHEAR HEAD SCREW DURING REASSEMBLY Suspensions TUAREG 660 SUSP 144 ...

Page 145: ... the upper steering triple clamp 2 and secure it by tightening the two screws 3 to torque Position the upper steering triple clamp 2 in its seat insert the bush 4 com plete with washer 5 and tighten it to torque Working from both sides tighten the screws 6 securing the stanchions to the upper triple clamp to torque TUAREG 660 Suspensions SUSP 145 ...

Page 146: ...onent wiring harnesses of the handlebars to the steering triple clamp with two clamps Steering bottom yoke Removing To remove the lower triple clamp it is necessary to first remove the front wheel complete with mud guard the upper triple clamp and the stanchions Then proceed as described Remove the steering safety plate 1 Remove the upper steering ring nut 2 using the special tool Specific tooling...

Page 147: ...ering 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 TUAREG 660 Suspensions SUSP 147 ...

Page 148: ...f ft 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...

Page 149: ...dlebar 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 Remove the handlebars and upper steering triple clamp Then proceed as described Remove the steering safety plate 1 Remove the upper steering ring nut 2 using the special tool Spec...

Page 150: ...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 that must be 250 100 g 0 55 0 22 lb in both directions Disassembling Place the motorcycle on a lifting jack in corre spondence of the oil sump and secure it with straps to the footrest Remove the upper triple clamp front wheel mud guard and stanchio...

Page 151: ...ooling 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 Remove the complete lower triple clamp 5 TUAREG 660 Suspensions SUSP 151 ...

Page 152: ... Remove the rubber dust ring 6 Remove the dust seal ring 7 Remove the bearing upper seat 8 Remove the inner ring of the bearing 9 complete with balls Suspensions TUAREG 660 SUSP 152 ...

Page 153: ...cover 13 Remove the upper seat of the lower bearing 14 from below using a stand ard bearing extractor DURING THE INSTALLATION OF THE BEARINGS IT IS NECESSARY TO GREASE THEM BE FORE INSERTING THEM IN THE STEERING HEADSTOCK Assembling To assemble the steering assembly proceed as described Place the dust cover 1 on the steering headstock Insert the lower seat of the bearing 2 and the inner ring of th...

Page 154: ...ricate the inserted seats with grease Insert the complete triple clamp 5 into the headstock Supporting the lower triple clamp in sert the inner ring of the bearing 6 complete with balls on the headstock and lubricate it Supporting the lower triple clamp lu bricate the upper seat 7 of the bearing and insert it on the headstock Suspensions TUAREG 660 SUSP 154 ...

Page 155: ...n it fully by hand Using the special tool pre tighten the ring nut 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 to a torque of 40 5 Nm 29 50 3 68 lbf ft Rotate the steering yoke all the way to the left and right to check that the ro tation is smooth and without jamming Specific tooling AP8140190 Steerin...

Page 156: ... Screw the upper steering ring nut 11 and align the grooves to be able to in sert the safety plate Insert the safety plate 12 Rear Shock absorbers Suspensions TUAREG 660 SUSP 156 ...

Page 157: ...AL USE CHECK AND IF NECESSARY 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 TURNS OF THE ADJUSTERS 2 3 ALWAYS START FROM THE MOST LOADED SET TING COMPLETE CLOCKWISE ROTATION OF THE AD JUSTER TO PRE...

Page 158: ...hicle in cor respondence with the linkages it is possible to access the hydraulic rebound damping adjuster 3 Turning clockwise the hydraulic re bound damping increases vice versa by turning anti clockwise it decreases 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 0 078 in Rebound adjustment adjuster 1 op...

Page 159: ...n proceed as described Unscrew the locking nut of the lower screw and remove it Unscrew the locking nut of the upper screw and remove it Slide the shock absorber from above to remove it Installing To install the shock absorber proceed as descri bed Position the shock absorber in place inserting it from above TUAREG 660 Suspensions SUSP 159 ...

Page 160: ...move the linkages after securing the front of the vehicle with straps use a scissor lift to support the centre of the vehicle and keep the rear shock absorber unloaded Then proceed as described SINGLE LINKAGE Working on the right hand side of the vehicle unscrew the nut fastening the single linkage to the dual linkage pull ing the screw out from the left hand side to remove it Suspensions TUAREG 6...

Page 161: ...ng the dual linkage to the swingarm and remove the screw from the right side Checking CAUTION CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED DAMAGED CRACKED AND OR DENTED REPLACE ALL DAMAGED COMPONENTS ROLLER BEARING CAGE Turn the roller bearings by hand The bearings must turn smoothly without impediment or noise No endfloat is permitted Replace any roller bearings with any of the problems descri...

Page 162: ...ed as described DUAL LINKAGE Insert the fixing screw of the dual link age to the swingarm from the right side and the lock nut from the opposite side tightening it to the prescribed torque Insert the screw fastening the shock absorber to the dual linkage and tight en it to the prescribed torque SINGLE LINKAGE Insert the fixing screw of the single link age to the swingarm from the left side and the...

Page 163: ... Insert the fixing screw of the single link age to the dual linkage from the left side and the lock nut from the opposite side tightening it to the prescribed tor que TUAREG 660 Suspensions SUSP 163 ...

Page 164: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 165: ...heel lift the motorcycle using an appropriate centre stand remove the brake callipers and proceed as descri bed Loosen the two screws 1 on the clamp of the left stanchion Remove the wheel pin 2 Keeping the wheel raised extract the wheel pin 2 TUAREG 660 Chassis CHAS 165 ...

Page 166: ...de of the wheel REMOVAL OF INTERNAL WHEEL COMPO NENTS To proceed with the removal of the internal wheel components proceed as described Working on the right side of the wheel remove the oil seal 5 Using special pliers remove the circlip 6 Chassis TUAREG 660 CHAS 166 ...

Page 167: ...on the bearing and screw the pin B Insert the second part C and the nut D Tighten the nut while keeping the pin A still to extract the bearing Remove the bearing 7 NOTE REPEAT THE OPERATION DESCRIBED ABOVE TO REMOVE THE BEARING ON THE OPPOSITE SIDE OF THE WHEEL Remove the internal spacer 8 TUAREG 660 Chassis CHAS 167 ...

Page 168: ... Checking FRONT WHEEL BEARINGS Check the bearings installed on the wheel CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR CHECKING ROTATION Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noise If one or both bearings do not fall within the control parameters Replace both wheel bearings CHECKING RADIAL ...

Page 169: ...E SEALS WITH COMPONENTS OF THE SAME TYPE WHEEL AXLE Use a dial gauge to check the wheel axle eccentricity Replace the wheel axle if the eccentricity exceeds the limit value Characteristic Maximum eccentricity 0 25 mm 0 0098 in Using a dial gauge check that the ra dial A and the axial B eccentricities of the rim do not exceed the limit value An excessive eccentricity is usually caused by worn or da...

Page 170: ...t determined by the markings which must face outwards as indicated Position the tone wheel 2 if present on the rim Carefully and progressively screw the five screws securing the tone ring brake disc following the order A B C D E CAUTION PAY CAREFUL ATTENTION TO TIGHTENING THE FIVE SCREWS ALWAYS PROCEED GRAD UALLY AND PROGRESSIVELY ON EACH SCREW Torque tighten the five screws in the order A B C D E...

Page 171: ...e rim using the appropriate punch insert the bearing 3 as far as it will go Specific tooling 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor Insert the circlip 4 Insert the oil seal 5 flush with the out side of the hub Insert the spacer 6 TUAREG 660 Chassis CHAS 171 ...

Page 172: ...ned the bearing 8 in its seat insert it as far as it will go using the appropriate punch CHECK THE FREE ROTATION OF BOTH BEARINGS Specific tooling 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor Insert the oil seal 9 flush with the out side of the hub Insert the spacer 10 Chassis TUAREG 660 CHAS 172 ...

Page 173: ... pin 12 Tighten the pin 12 to the prescribed torque Tighten the two screws 13 on the clamp of the right stanchion to the pre scribed torque Rotate the wheel a few times to check that it does not stick Rear wheel TUAREG 660 Chassis CHAS 173 ...

Page 174: ...rom 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 and the washer 4 Supporting the wheel and working from the right side remove the wheel pin 5 complete with both chain tensioners 6 Chassis TUAREG 660 CHAS 174 ...

Page 175: ...MOVAL 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 spacer 10 present be tween the rear sprocket and the flange Remove the flexible coupling rubber inserts 11 TUAREG 660 Chassis CHAS 175 ...

Page 176: ...rew the five screws 12 and re move the flange 13 Remove the spacer 14 Unscrew the three screws 15 and re move the tone ring 16 Undo the five screws 17 and remove the brake disc 18 Chassis TUAREG 660 CHAS 176 ...

Page 177: ...eel remove the oil seal 19 Using special pliers remove the circlip 20 Using a generic puller proceed with the extraction of the bearing as descri bed Insert the first part of the tool A on the bearing and screw the pin B Insert the second part C and the nut D Tighten the nut while keeping the pin A still to extract the bearing TUAREG 660 Chassis CHAS 177 ...

Page 178: ...HE WHEEL Remove the internal spacer 22 REAR SPROCKET SUPPORT DISASSEMBLY Having removed the sprocket support from the wheel remove the external spacer 23 Block the sprocket support in a vice provided with protective jaws and re move the five fixing screws 24 of the chain sprocket guard Chassis TUAREG 660 CHAS 178 ...

Page 179: ...Remove the five spring washers 25 Remove the chain guard 26 Remove the sprocket 27 Remove the oil seal 28 TUAREG 660 Chassis CHAS 179 ...

Page 180: ...OTATION Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noise If one or both bearings do not fall within the control parameters Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE Check the radial and axial play Axial play minimal axial play is permitted Radial none If one or both be...

Page 181: ...25 mm 0 0098 in REAR WHEEL RIM Using a dial gauge check that the ra dial A and the axial eccentricity B of the rim 2 do not exceed the limit val ue An excessive eccentricity is usually caused by worn or damaged bearings Replace the rim 2 if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 0 8 mm 0 031 in Installing To mou...

Page 182: ...r as it will go Specific tooling 020376Y Adaptor handle 020655Y Adaptor 62x68 mm Insert the circlip 3 Position the oil seal 4 flush with the outside of the rear sprocket support Position the sprocket 5 on the sprock et support Chassis TUAREG 660 CHAS 182 ...

Page 183: ... 6 on the sprocket support Position the five spring washers 7 on the sprocket support Torque tighten the five chain rear sprocket guard fixing nuts in the order A B C D E Insert the external spacer 9 TUAREG 660 Chassis CHAS 183 ...

Page 184: ...d from the right side as described Position the bearing 10 in its seat and use the appropriate punch to insert as far as it will go Specific tooling 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor Insert the circlip 11 Insert the oil seal 12 flush with the outside of the hub Insert the spacer 13 Chassis TUAREG 660 CHAS 184 ...

Page 185: ... the internal wheel components proceed as described Position the brake disc 16 on the hub making sure of the correct orientation determined by the markings which must face outwards Carefully and progressively screw the five screws securing the tone ring clutch plate following the order A B C D E CAUTION PAY CAREFUL ATTENTION TO TIGHTENING THE FIVE SCREWS ALWAYS PROCEED GRADUALLY AND PRO GRESSIVELY...

Page 186: ...e left side position the flange 18 on the hub insert the five screws and tighten them to the speci fied torque in the following order A B C D E Position the flexible coupling rubber in serts 19 on the flange Insert the spacer 20 in the flange in the direction indicated Chassis TUAREG 660 CHAS 186 ...

Page 187: ...tion the wheel 22 in its seat in serting the chain 23 on the sprocket Working from the right side of the mo torcycle lift the wheel and insert the pin 24 complete with the chain tensioner 25 Insert the left chain tensioner 26 TUAREG 660 Chassis CHAS 187 ...

Page 188: ... and tighten the locking nuts 30 Check that the vertical deflection of the bottom section of the chain measured at a distance of 320 mm 12 59 in from the centre of the rear wheel axle along imaginary line between centres of front and rear sprockets is approximately 48 mm 1 88 in Check that the distance set is the same on both sides Chassis TUAREG 660 CHAS 188 ...

Page 189: ...removal of the swingarm it is necessary to first remove the rear wheel rear mudguard and chain cover Then proceed with the removal of the rear brake calliper complete with sup port by disconnecting the brake line and the rear ABS sensor wiring har ness from the three cable guides on the swingarm Position a rear stand to support the swingarm and unscrew the nut 1 and remove the screw 2 fixing the d...

Page 190: ...icle and supporting the swingarm ex tract the swingarm pin 6 Remove the swingarm 7 taking care to recover the flat washers on both sides 8 If necessary to check or eventually re place the roller bearings in the swing arm working from both sides remove the T bush 9 and the shoulder ring 10 Chassis TUAREG 660 CHAS 190 ...

Page 191: ...sliders Checking CAUTION CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED DAMAGED CRACKED AND OR DENTED REPLACE ALL DAMAGED COMPONENTS ROLLER CASINGS Turn the roller casings manually they must rotate smoothly continuously and silently There must be no axial clearance Replace the roller casings that present these problems Apply grease on the rollers GASKETS Check that the gaskets are in good conditi...

Page 192: ...sassembly 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 contact parts LEFT SIDE The roller bearings 1 2 must be positioned as per detail A resting one on top of the other on the inner face in the centre line RIGHT SIDE The roller bearing 3 must be positioned as per detail B at a depth of 15 5 ...

Page 193: ...sides position the flat washers 8 on the swingarm 7 paying attention to the correct align ment The machined part must be fac ing the swingarm Then insert the swingarm into its seat Working from the right side of the ve hicle supporting the swingarm insert the swingarm pin 9 making sure that it is inserted as far as it will go Position a rear stand to support the swingarm TUAREG 660 Chassis CHAS 19...

Page 194: ...d fasten it using the appropriate screw 13 and relative nut 14 tight ening it to torque Reassemble the rear brake calliper on the swingarm connecting the brake hose and the rear ABS sensor wiring harness to the three indicated cable guides reassemble the rear mudguard the chain guard and the rear wheel checking the correct tension of the chain Pinion Chassis TUAREG 660 CHAS 194 ...

Page 195: ...e protection 2 and re move it Turn the retainer 3 outward anti clockwise and remove it to disconnect the gear shift lever tie rod 4 from the transmission lever Unscrew the three fixing screws 5 of the front sprocket casing 6 taking care to recover the T bushes 7 Remove the front sprocket casing 6 after having disconnected the breather pipe 8 TUAREG 660 Chassis CHAS 195 ...

Page 196: ...e T bush 11 and the cup spring washer 12 Remove the front sprocket 13 from the transmission shaft and free it from the drive chain Remove the spacer 14 from the transmission shaft During reassembly pay attention to the correct orientation of the front sprocket Chassis TUAREG 660 CHAS 196 ...

Page 197: ...e chain also Installing To proceed with the installation of the front sprock et proceed as described Insert the spacer 1 on the transmis sion shaft Assemble the front sprocket 2 with the drive chain 3 and insert it on the transmission shaft making sure of the correct orientation The machined part must be facing the engine as indicated Insert the chain guide TUAREG 660 Chassis CHAS 197 ...

Page 198: ...it to the prescribed torque Position 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 Connect the gear shift rod 11 insert the retainer 12 and turn it clockwise to fasten it Chassis TUAREG 660 CHAS 198 ...

Page 199: ...in Removing The transmission chain although closed has a different coloured hammerlock where provided which should be used to perform opening disas sembling procedures NOTE WHERE PRESENT THE HAMMERLOCK 1 MAY ALSO BE IDENTIFIED BY A SIGN 2 APPLIED IN THE MOUNTING LINES DURING MANUFACTURING To dismantle and remove the chain proceed as follows Partially remove the pins 3 using a generic chain breaker...

Page 200: ... Remove the outer plate 4 Remove the outer O ring rings 5 Remove the inner plate 6 Collect the inner O ring rings 7 and completely remove the transmission chain Chassis TUAREG 660 CHAS 200 ...

Page 201: ... chain stretch of 1 5 3 Chain with chain stretch of 3 which must therefore be replaced in accordance with ap plicable legislation Perform the procedure described as follows to check chain wear Tauten the chain Place the jaws of the tool on the rollers at the opposite ends of a STRAIGHT length of chain consisting of 8 chain links Check that the notch on the sliding jaw matches the correct marking o...

Page 202: ...LD SEIZE THE CHAIN Check that the links in the transmission chain are not seized and that it can move in both directions Use a generic clincher to re tighten the pins of the link checking riveting at points A 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 Chassis TUAREG 660 CHAS 202 ...

Page 203: ... 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 48 mm 1 88 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 THIS CASE THE CHAIN SHOULD BE RE PLACED LUBRICATE THE CHAIN REGULARLY TO PREVE...

Page 204: ...hat the dis tance is the same on both sides Tighten the two lock nuts 2 Tighten the nut 1 Check the chain clearance Chain sliders To remove the chain sliders follow the procedure described below CHAIN GUARD Place the vehicle on the specific rear support stand optional Remove the three fixing screws Remove the chain guard Chassis TUAREG 660 CHAS 204 ...

Page 205: ...ing screws chain guide along with the cups Remove the chain guide CHAIN ROLLER It is not necessary to remove the sup port plate in order to remove the chain roller Unscrew the fixing screw to re move the roller To assemble the chain sliders carry out the procedures described above in reverse order Pedaline TUAREG 660 Chassis CHAS 205 ...

Page 206: ... lever 2 taking care to retain the two rubber o rings 3 and the washer 4 Turn the retainer 5 outward anti clockwise and remove it to disconnect the transmission lever from the shift lever Remove the gear shift lever Remove the split pin 6 of the pin and the washer 7 CAUTION ALWAYS USE A NEW SLIT PIN DURING REASSEMBLY After removing the pin 8 extract the foot rest 9 complete with spring 10 Chassis ...

Page 207: ... FROM THE SUPPORT PLATE Loosen the fixing nut 11 of the swing arm pin Unscrew and remove the lower screw 12 and collect the spacer 13 Completely unscrew the nut 11 col lect the flat washer 14 and remove the support plate 15 Unscrew the screw 16 in order to re move the chain roller 17 TUAREG 660 Chassis CHAS 207 ...

Page 208: ... the two fixing screws 1 of the rear brake master cylinder 2 Release the brake lever return spring 3 and remove it Unscrew the fixing screw 4 of the brake lever 5 taking care to retain the two rubber o rings 6 and the washer 7 Remove the split pin 6 of the pin and the washer 7 CAUTION ALWAYS USE A NEW SLIT PIN DURING REASSEMBLY Chassis TUAREG 660 CHAS 208 ...

Page 209: ...t rest THE RUBBER PART CAN ALSO BE REMOVED WITHOUT REMOVING THE FOOT REST FROM THE SUPPORT PLATE Keeping the nut 11 still unscrew and remove the screw 12 that secures the exhaust manifold to the support plate Proceed with the complete removal of the exhaust to access the screw un derneath the support plate Undo and remove the screw 13 TUAREG 660 Chassis CHAS 209 ...

Page 210: ...arm pin Take care to collect the spacers 14 on both sides Unscrew the two fixing screws 15 of the rear brake switch to remove the right support plate 16 PASSENGER FOOTRESTS THE OPERATIONS DESCRIBED BELOW RE FER TO A SINGLE FOOTREST BUT ARE VAL ID FOR BOTH Remove the split pin 1 of the pin and the washer 2 CAUTION ALWAYS USE A NEW SLIT PIN DURING REASSEMBLY Remove the pin 3 Chassis TUAREG 660 CHAS ...

Page 211: ...s 4 are aligned correctly before dismantling the pedal taking care not to lose the ball 5 and the spring 6 Unscrew and remove the two screws 7 to separate the rubber part from the footrest Remove the retainer plate 8 of the screws from the rubber part TUAREG 660 Chassis CHAS 211 ...

Page 212: ...Installazione LEFT RIDER FOOTREST To assemble and install the left rider footrest pro ceed as follows Position the chain roller 1 and tighten the screw 2 to the prescribed torque Position the support plate 3 insert the flat washer 4 and manually screw the nut 5 Chassis TUAREG 660 CHAS 212 ...

Page 213: ...he screw 7 screwing it manually Tighten part the nut 5 to the prescri bed torque Tighten the screw 7 to the prescribed torque Assemble the rubber part on the foot rest paying attention to insert it correct ly in point A and then point B TUAREG 660 Chassis CHAS 213 ...

Page 214: ...new split pin 12 locking it by bending the ends as shown Connect the transmission lever to the gear shift lever and after inserting the retainer 13 turn it clockwise to secure it Insert the gear shift lever fixing pin 14 complete with the two rubber o rings 15 and washer 16 Tighten the pin to the prescribed tor que Chassis TUAREG 660 CHAS 214 ...

Page 215: ...garm pin 2 into the support plate 3 taking care to insert the spacers 4 on both sides checking the correct orientation as in the photo Insert the flat washer 5 and manually screw the nut 6 Insert the lower fixing screw 7 of the plate to the frame and screw it man ually Then tighten the nut 6 swingarm pin and then of the screw 7 to the pre scribed torque TUAREG 660 Chassis CHAS 215 ...

Page 216: ...on the foot rest paying attention to insert it correct ly in point A and then point B Insert the spring 10 on the footrest 11 checking the correct orientation and insert the pin 12 Position the washer 13 on the pin and insert a new split pin 14 locking it by bending the ends as shown Chassis TUAREG 660 CHAS 216 ...

Page 217: ...osition the rear brake master cyl inder in its seat and tighten the two fixing screws 19 to torque PASSENGER FOOTRESTS THE OPERATIONS DESCRIBED BELOW RE FER TO A SINGLE FOOTREST BUT ARE VAL ID FOR BOTH To assemble and install the passenger footrest proceed as follows Position the footrest support 1 and secure by tightening the two screws 2 to torque TUAREG 660 Chassis CHAS 217 ...

Page 218: ...ng the two screws 4 to torque Assemble the footrest opening closing components checking the correct ori entation of the plates 5 before insert ing the spring 6 and the ball 7 While pressing the side plates position the complete footrest on the support and insert the pin 8 Chassis TUAREG 660 CHAS 218 ...

Page 219: ...wn Stand Side stand REMOVAL To remove the side stand proceed as described Disconnect and remove the two return springs 1 from the stand Unscrew the nut 2 and remove the stand sensor 3 Remove the fastening nut 4 from the centre stand screw taking care to col lect the washer 5 TUAREG 660 Chassis CHAS 219 ...

Page 220: ...e washer 7 NOTES FOR THE REFIT PHASE Check the correct positioning of the side stand sensor in particular that the sensor pin is engaged in the hole on the stand CAUTION INCORRECT POSITIONING OF THE SIDE STAND SENSOR CAN GENERATE THE STAND OPEN SIGNAL THERE FORE INHIBIT THE START Chassis TUAREG 660 CHAS 220 ...

Page 221: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 222: ...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 appropriate safety margin Under no circumstances can the ABS system compensate for the rider s misjudgement or improper use of brakes The ABS system can be deactivated only when the vehicle is stationary and in the OFF ROAD riding mode or active If ...

Page 223: ...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 instru ment panel check cycle the ABS warning lamp flashes until the vehicle reaches a speed of 3 1 mph 5 km h after which it goes out If with the ABS system activated level 1 2 the ABS warning lamp lights steadily or continues to flash eve...

Page 224: ...STANCE BETWEEN TONE WHEEL AND SENSOR IS THE ONE SPECIFIED FOR CHECKING AND ADJUSTMENT CONTACT AN Authorised Apri lia Workshop 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...

Page 225: ...Operating diagram ABS functional diagram key 1 Front system circuit 2 Rear system circuit 3 Front brake callipers 4 Rear brake calliper TUAREG 660 Braking system BRAK SYS 225 ...

Page 226: ...r one The ABS inlet valve 9 10 is normally open and it is closed only when the system intervenes to avoid wheel locking The exhaust valve 11 12 is normally closed and it is opened only when the system in tervenes to avoid wheel locking With the system in stand by mode the ABS processor controls the wheel speed instant by instant to assess any slippage of the wheels When in standby the system does ...

Page 227: ...ng increasing vehicle braking stability when compared to a traditional braking system The ABS system improves vehicle control provided that the physical limits of vehicle grip on the road are not exceeded The rider is fully responsible for riding at a suitable speed based on weather and road conditions always leaving an appropriate safety margin Under no circumstances can the ABS system compensate...

Page 228: ...l tank the side protections of the frame the ECU and its support Then proceed as described Disconnect the purge valve 1 from the frame Disconnect the fuel pipe 2 from the cable guide Disconnect the wiring harness 3 of the starter motor from the two cable guides Braking system TUAREG 660 BRAK SYS 228 ...

Page 229: ...val procedure of the ABS modulator Unscrew and remove the four fixing screws 6 of the brake lines to the modulator taking care to recover the washers 7 EACH SCREW IS EQUIPPED WITH TWO WASHERS Remove the cover 8 Working from both sides unscrew the nut 9 recovering the washer and re move the screw 10 TUAREG 660 Braking system BRAK SYS 229 ...

Page 230: ...PIPES SO THAT THEY ARE REFITTED CORRECTLY ON THE NEW MODULATOR CONTROL UNIT AFTER REPLACING THE MODULATOR CONTROL UNIT THE ABS SYSTEM MUST BE BLED MORE OIL IS REQUIRED TO BLEED THE ABS SYSTEM THAN A CONVENTIONAL SYSTEM FOR THIS REASON CAREFULLY CHECK THE OIL LEVEL IN THE BRAKE TANK If even after bleeding the front brake lever feels spongy the secondary circuit in the ABS control unit must be bled ...

Page 231: ...tion has been successful the warning light should come on and flash slowly In the event of a fault with the diagnostic tool disconnected the warning light should be permanently lit Connect the diagnostic tool and check for errors ABS CONTROL UNIT CONNECTOR INSERTION PROCEDURE The initial position of the connector coupling lever must be as indicated in the figures Place the connector on the opposit...

Page 232: ...he operation as described in the A2 A3 images We recommend creating a template in order to ensure that the connector is inserted correctly It is possible to check the correct in sertion of the connector on the motor cycle by verifying that the yellow line is Flush with the connector Removal To remove the rear brake calliper it is necessary to first remove the rear wheel and drain the rear brake sy...

Page 233: ...liper Unscrew and remove the special screw complete with washers fixing the brake hose to the calliper CAUTION ALWAYS USE NEW SEALING WASHERS DURING REAS SEMBLY Remove the brake calliper complete with support from the swingarm To separate the brake calliper from the support follow the procedure described below Remove the cotter pin from the pin TUAREG 660 Braking system BRAK SYS 233 ...

Page 234: ... Using a punch extract the locking pin of the pads Remove the brake pads Separate the brake calliper from the support Remove the rubber grommet from the calliper Braking system TUAREG 660 BRAK SYS 234 ...

Page 235: ... port NOTE DURING REASSEMBLY LUBRICATE THE RUBBER GROMMETS ENOUGH TO INSERT THEM IN THEIR SEATS AND THE SLIDING PINS Installing To install the rear brake calliper it must be assem bled before positioning it in place Position the metal plate on the support checking for correct orientation TUAREG 660 Braking system BRAK SYS 235 ...

Page 236: ...G THE RUBBER GROMMET IF DETERIORATED OR HAS CRACKS REPLACE IT WITH A NEW ONE Lubricate the rubber grommet as nec essary and insert it on the brake callip er NOTE CHECK THE CONDITION BEFORE POSITIONING THE RUBBER GROMMET IF DETERIORATED OR HAS CRACKS REPLACE IT WITH A NEW ONE Lubricate the two pins sufficiently and connect the brake calliper to the sup port Braking system TUAREG 660 BRAK SYS 236 ...

Page 237: ...and check they have been fitted cor rectly Insert the brake pads retaining pin Insert the split pin in the retaining pin of the brake pads Position the brake calliper complete with support on the swingarm TUAREG 660 Braking system BRAK SYS 237 ...

Page 238: ...rt the ABS sensor in its seat and secure it by tightening the screw to the prescribed torque Fill the rear brake system checking its level and restore the correct position ing of the wiring harness near the breather screw blocking it with the pro tection cap as indicated After reassembling the rear wheel check the distance between the tone wheel and the ABS sensor Characteristic Distance between t...

Page 239: ...ving the front brake calliper it is necessary to drain the front brake system Then proceed as de scribed Unscrew and remove the special screw complete with washers fixing the brake hose to the calliper CAUTION ALWAYS USE NEW SEALING WASHERS DURING REAS SEMBLY Undo and remove the two screws fixing the front brake calliper to the stanchion of the fork Remove the brake calliper together with the supp...

Page 240: ...he support follow the procedure described below Remove the cotter pin from the pin Using a punch extract the locking pin of the pads Remove the brake pads Separate the brake calliper from the support Braking system TUAREG 660 BRAK SYS 240 ...

Page 241: ... grommet from the support Remove the metal plate from the brake calliper Remove the metal plate from the sup port NOTE DURING REASSEMBLY LUBRICATE THE RUBBER GROMMETS ENOUGH TO INSERT THEM IN THEIR SEATS AND THE SLIDING PINS TUAREG 660 Braking system BRAK SYS 241 ...

Page 242: ... orienta tion Lubricate the rubber grommet as nec essary and insert it on the support NOTE CHECK THE CONDITION BEFORE POSITIONING THE RUBBER GROMMET IF DETERIORATED OR HAS CRACKS REPLACE IT WITH A NEW ONE Lubricate the rubber grommet as nec essary and insert it on the brake callip er NOTE CHECK THE CONDITION BEFORE POSITIONING THE RUBBER GROMMET IF DETERIORATED OR HAS CRACKS REPLACE IT WITH A NEW ...

Page 243: ...he brake calliper to the sup port Position the brake pads in the calliper and check they have been fitted cor rectly Insert the brake pads retaining pin Insert the split pin in the retaining pin of the brake pads TUAREG 660 Braking system BRAK SYS 243 ...

Page 244: ...ting the brake line Insert the special screw complete with new washers fixing the brake line and tighten it to the prescribed torque WARNING PAY ATTENTION WHEN CONNECTING THE BRAKE LINES ON THE RIGHT CALLIPER THE BRAKE LINE 1 THAT CONNECTS THE TWO CALLIPERS MUST BE INSERTED FIRST AND THEN THE LINE 2 THAT CONNECTS THE RIGHT CALLIPER TO THE MODULATOR Fill the front brake system and check the level R...

Page 245: ...ing the minimum thickness 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 TUAREG 660 Braking s...

Page 246: ... FLAT SURFACE MUST BE IN CONTACT WITH THE RIM WHILE THE MILLED SURFACE MUST BE FACING OUTWARDS Insert the five screws and tighten them to torque in the order shown A B C D E Front brake disc Removal To remove the front brake disc after removing the wheel proceed as described THE FOLLOWING OPERATIONS REFER TO ONE DISC BUT APPLY TO BOTH Remove the five fixing screws 1 of the tone wheel if applicable...

Page 247: ...or wear by measuring the minimum thickness with a micro meter in different points If the mini mum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 mm 0 16 in Using a dial gauge check that the max imum oscillation of the disc does not exceed the tolerance otherwise re place it Disc oscillation tolerance 0 15 mm 0 0059 in TUA...

Page 248: ...on Carefully and progressively screw the five screws securing the tone ring brake disc following the order A B C D E CAUTION PAY CAREFUL ATTENTION TO TIGHTENING THE FIVE SCREWS ALWAYS PROCEED GRADUALLY AND PRO GRESSIVELY ON EACH SCREW Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM RIGHT AND LEFT SIDE ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPE...

Page 249: ...D ALLOW BRAKE FLUID TO ESCAPE Installing THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM RIGHT AND LEFT SIDE ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS REPLACING THE PADS OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE STABILITY AND SAFETY POSING SERIOUS DANGER FOR PEOPLE OBJECTS AND THE VE HICLE ITSELF CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE CALLIP...

Page 250: ...ed cor rectly Insert the locking pin 2 Insert split pin 3 in the pin Check the correct operation of the brake system Rear brake pads Removal To remove the rear brake pads follow the proce dure described below Remove the cotter pin 1 Braking system TUAREG 660 BRAK SYS 250 ...

Page 251: ...THE BRAKE PADS HAVE BEEN REMOVED AS THIS MAY FORCE THE PISTONS OUT FROM THEIR SEATS AND ALLOW BRAKE FLUID TO ESCAPE Installing Insert the brake pads 1 in the calliper and check they have been fitted cor rectly Insert the locking pin 2 TUAREG 660 Braking system BRAK SYS 251 ...

Page 252: ...ERS 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 sponginess of the brake and by poor braking CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING THE BRAKE CALLIPERS AND RESTORING THE BREAKING SYSTEM TO ITS ...

Page 253: ...h the lever Repeat the operation until the are no air bubbles in the fluid going into the container NOTE WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit a...

Page 254: ...ESTORE 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 NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover of the bleed valve Insert the transpare...

Page 255: ...M 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 operate and release the rear brake pedal until the message of diagno...

Page 256: ...to the wiring harness Unscrew the fixing screw of the brake line complete with the two washers Unscrew the two fixing screws of the U bolt to completely remove the brake master cylinder Installing To install the front master cylinder carry out the procedures described above in reverse order Then fill the system and bleed it PAY ATTENTION TO USE NEW WASHERS TO FASTEN THE SCREW OF THE BRAKE LINE Rea...

Page 257: ...2 to access the fixing screw of the rear brake fluid res ervoir Keeping the screw 3 still unscrew the nut 4 to disconnect the rear brake flu id reservoir and remove the right frame cover Unscrew the fixing screw 5 of the brake line complete with the two wash ers 6 Remove the safety O ring 7 from the pin that blocks the brake pump control rod TUAREG 660 Braking system BRAK SYS 257 ...

Page 258: ... in reverse order Then fill the system and bleed it PAY ATTENTION TO USE NEW WASHERS TO FASTEN THE SCREW OF THE BRAKE LINE Brake system lines Removal To remove the fuel pipes it is necessary to first remove the fuel tank the side fairings and the right side protection of the frame Then drain the entire brake system and proceed as described MODULATOR REAR BRAKE CALLIPER BRAKE LINE Unscrew the fixin...

Page 259: ...LINE 6 IS POSITIONED EXTERNAL LY Disconnect the brake line from the two cable guides 7 Disconnect the brake line from the three cable guides 7 Unscrew the fixing screw 9 complete with the two washers 10 and remove the brake line 11 MODULATOR REAR BRAKE MASTER CYL INDER BRAKE LINE Unscrew the fixing screw 1 with the two washers 2 TUAREG 660 Braking system BRAK SYS 259 ...

Page 260: ...ITIONED IN TERNALLY Unscrew the fixing screw 7 complete with the two washers 8 and remove the brake line 9 MODULATOR FRONT BRAKE MASTER CYL INDER BRAKE LINE Unscrew the fixing screw 1 with the two washers 2 Unscrew the three screws 3 and re move the support plate 4 of the en gine to the frame to facilitate the removal of the cable clamp under neath Braking system TUAREG 660 BRAK SYS 260 ...

Page 261: ...the two rubber grommets 7 that fasten the brake line to the wiring harness Unscrew the fixing screw 8 complete with the two washers 9 and remove the brake line 10 MODULATOR FRONT BRAKE CALLIPER BRAKE LINE Unscrew the fixing screw 1 with the two washers 2 TUAREG 660 Braking system BRAK SYS 261 ...

Page 262: ...able clamp under neath Unscrew the two screws 5 and re move the retainer plates 6 of the front brake lines Remove the metal cable guide 7 on the front mudguard to free the brake lines Remove the cable guides 8 that se cure the front brake line with the wiring harness of the ABS sensor Braking system TUAREG 660 BRAK SYS 262 ...

Page 263: ...e of the two callipers 11 Cut the clamp 12 and remove the brake line 13 Assembly To install the brake lines carry out the procedures described above in reverse order Then fill the system and bleed it PAY ATTENTION TO USE NEW WASHERS TO FASTEN THE SCREWS OF THE BRAKE LINES TUAREG 660 Braking system BRAK SYS 263 ...

Page 264: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 265: ... proceed as described Remove the five fixing screws 1 of the water pump cover Remove the water pump cover 2 complete with gasket 3 Unscrew the rotor 4 and remove it Remove the flywheel cover 5 com plete with gasket 6 TUAREG 660 Cooling system COOL SYS 265 ...

Page 266: ...r 8 From the outside of the cover using a punch remove the sealing ring 9 Remove the oil seal 10 Installing To proceed with the installation of the water pump proceed as described Apply a light coat of grease to the in side of the oil seal 1 Cooling system TUAREG 660 COOL SYS 266 ...

Page 267: ...oling 020376Y Adaptor handle 020414Y 28 mm punch Apply a light coat of grease to the slid ing surface of the oil pump gear 2 Insert the flat washer 3 on the water pump gear Apply a light coat of grease to the sur face of the flat washer TUAREG 660 Cooling system COOL SYS 267 ...

Page 268: ...water pump Specific tooling 021037Y Water pump seal insertion tool Insert the gear complete with tool on the cover Insert the sealing ring 4 Insert the second part of the tool B and the nut C Specific tooling 021037Y Water pump seal insertion tool Cooling system TUAREG 660 COOL SYS 268 ...

Page 269: ...or To remove the radiator it is necessary to remove the fuel tank sump guard and the side fairings Then proceed as described Remove the expansion tank cap 1 Operating on the left side of the motor cycle remove the screw 2 to com pletely drain the cooling system taking care to collect the metal washer DURING REPLACEMENT USE A NEW SEAL ING WASHER TUAREG 660 Cooling system COOL SYS 269 ...

Page 270: ...emove the two fastening screws 5 of the radiator to the support Move the radiator towards the left side of the vehicle to disengage it from the guide pin Unscrew the two fixing screws 6 of the voltage regulator to be able to move it away and have access to the connector of the right electric fan Cooling system TUAREG 660 COOL SYS 270 ...

Page 271: ... side of the vehicle Removing the expansion tank To remove the expansion tank it is necessary to remove the fuel tank free the filter box without dis connecting it from the manifolds remove the side fairings and drain the system Then proceed as described Remove the metal clamps 1 and dis connect the hoses 2 USE NEW METALLIC CLAMPS DURING IN STALLATION TUAREG 660 Cooling system COOL SYS 271 ...

Page 272: ...val in reverse order 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 Remove the two cover fixing screws Cooling system TUAREG 66...

Page 273: ...integrity and effec tive operation insert the thermostatic valve in its seat taking care of its cor rect positioning Replace the cover and tighten the two screws to the prescribed torque 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 TUAREG 660 Cooling system COOL SYS 273 ...

Page 274: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 275: ... released lift and slide off the saddle backwards CAUTION BEFORE LOWERING AND LOCKING THE SADDLE MAKE SURE THAT THE IGNITION KEY HAS NOT BEEN FORGOT TEN IN AN UNSUITABLE POSITION UNDER THE SADDLE Hand guards To remove the handguards proceed as follows RIGHT HAND GUARD Remove the front fixing screw 1 Unscrew the screw 2 with the T bush 3 Remove the handguards 4 and the anti vibration weight 5 TUARE...

Page 276: ...Remove the support 8 for the handg uard taking care to recover the T bush 9 LEFT HAND GUARD Remove the front fixing screw 1 Unscrew the screw 2 with the T bush 3 Remove the handguards 4 and the anti vibration weight 5 Bodywork TUAREG 660 BODYW 276 ...

Page 277: ...everse order Devioluci To 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 Remove the handguards and the supports of the anti vibration weights Then proceed as descri bed RIGHT SWITCH CLUSTER REMOVAL TUAREG 660 Bodywork BODYW 277 ...

Page 278: ... the five screws 1 Remove the two screws 2 that fasten the right instrument panel support to the chassis Remove the two rubber cable clamps Remove the clamps 3 to release the wiring Disconnect the throttle control connec tor 4 Bodywork TUAREG 660 BODYW 278 ...

Page 279: ...itch cluster con nector 6 from the guide on the instru ment panel support and disconnect it Unscrew the fixing screw 7 of the right switch cluster and slide it off the han dlebar to remove it LEFT SWITCH CLUSTER REMOVAL Working on the left hand side of the motorcycle remove the five screws 1 TUAREG 660 Bodywork BODYW 279 ...

Page 280: ...s 2 that fasten the right instrument panel support to the chassis Remove the two rubber cable clamps 3 Remove the clamps 4 to release the wiring Using compressed air remove the left hand grip 5 Bodywork TUAREG 660 BODYW 280 ...

Page 281: ...ing the rear view mirrors Rest the vehicle on its stand Lift the rubber protection 1 Loosen the fastening nut 2 by ensur ing that the threaded clamp 3 cannot rotate Slide up and remove the complete rear view mirror unit 4 Repeat the procedure to remove the other rear view mirror if necessary UPON REFITTING AND BEFORE TIGHTENING THE LOCK ING NUT MAKE SURE THAT THE REAR VIEW MIRROR SUPPORT STEM IS A...

Page 282: ...plete with washers 4 securing the instru ment panel Disconnect the connector 5 of the in strument panel 6 and remove it Headlight assy To remove the front light cluster first remove the tank cover the air ducts the top fairing and the instrument panel visor Then proceed as descri bed Working on both sides of the vehicle remove the fixing screws 1 of then headlight to the instrument panel sup port ...

Page 283: ...cluster 4 from the headlight bezel 5 The two parts of the headlight bezel can be separated by unhooking them from each other Working from both sides of the light cluster unscrew the screws 6 to re move the covers 7 After reassembling check that the headlight beams are aimed correctly See also Headlight adjustment TUAREG 660 Bodywork BODYW 283 ...

Page 284: ...xing screw and remove the turn indicator Disconnect the connector and remove the turn indicator To remove the turn indicator mount unscrew the two fixing screws indica ted REAR TURN INDICATORS REMOVAL THE OPERATIONS DESCRIBED BELOW RE FER TO A SINGLE TURN INDICATOR BUT ARE VALID FOR BOTH Undo the two fixing screws of the li cence plate holder fastener and re move it Bodywork TUAREG 660 BODYW 284 ...

Page 285: ... re move the indicator Disassembling the lock To remove the saddle lock after removing the saddle proceed as described After disconnecting the left tail fairing disconnect the cable 1 from the lock block 2 Unscrew the screw 3 complete with fixing washer 4 of the lock control lev er TUAREG 660 Bodywork BODYW 285 ...

Page 286: ...the lock control lever 5 and the spring 6 Remove the fork spring 7 Remove the cable support plate 8 Working from the external side of the left tail fairing remove the lock block 9 Bodywork TUAREG 660 BODYW 286 ...

Page 287: ... fasten the licence plate holder Disconnect the connector 2 of the rear light cluster and the connectors 3 of the turn indicators to remove the li cense plate holder Remove the screw 4 located under the tail fairing On both sides of the vehicle remove the side fixing screws 5 of the tail fair ing TUAREG 660 Bodywork BODYW 287 ...

Page 288: ...ve the four screws 7 in order to separate the tail fairing 8 from the rear light cluster 9 License plate light The license plate light is incorporated inside the rear light cluster therefore if it needs to be replaced due to a malfunction carry out the removal procedure of the rear light cluster Bodywork TUAREG 660 BODYW 288 ...

Page 289: ...r both Remove the two screws with relative washers and separate the side panel from the side tail fairing Side fairings To remove the side fairings proceed as described THE FOLLOWING OPERATIONS REFER TO ONE SIDE BUT ARE VALID FOR BOTH Remove the clip 1 Remove the lateral fastener screw 2 Remove the internal screw 3 that se cures the side fairing to the radiator TUAREG 660 Bodywork BODYW 289 ...

Page 290: ...m the pin 5 on the tank and at the same time disconnect the pin 6 on the side fair ing from the engine mount Unscrew the three screws 6 and re move the radiator grille closure 7 Unscrew the two screws 8 to sepa rate the internal part from the external part of the side fairing Bodywork TUAREG 660 BODYW 290 ...

Page 291: ...sten the licence plate holder Disconnect the connector 2 of the rear light cluster and the connectors 3 of the turn indicators to remove the li cense plate holder Splash guard To remove the splash guard follow the procedure described below Unscrew the two fixing screws and re move the splash guard TUAREG 660 Bodywork BODYW 291 ...

Page 292: ...he sump guard follow the procedure described below Remove the two front screws 1 Supporting the sump guard remove the two rear screws 2 Remove the sump guard 3 Remove the four rubber grommets 4 Bodywork TUAREG 660 BODYW 292 ...

Page 293: ...Fuel tank To remove and disassemble the fuel tank it is necessary to remove the saddle the battery and the side fairings Then proceed as described Remove the fuel tank cap 1 Remove the three fixing screws 2 of the tank cover Remove the two rear screws 3 TUAREG 660 Bodywork BODYW 293 ...

Page 294: ...Remove the tank cover 5 Working on both sides remove the two fastening clips 6 of the air ducts Disconnect the pin 7 of the air duct from the tank Slide off the front part of the air duct 8 to remove it Bodywork TUAREG 660 BODYW 294 ...

Page 295: ...11 discon nect the OBDII connector 12 and re move the battery box 13 Disconnect the electric connector 14 of the fuel pump and release the wiring harness from the cable guide 15 Disconnect and remove the safety plate 16 of the fuel pipe 17 and dis connect it from the fuel pump TUAREG 660 Bodywork BODYW 295 ...

Page 296: ... fuel pipe Extract the hose clamp 20 and dis connect the breather pipe 21 Remove the metallic clamp 22 and disconnect the fuel vapour recovery pipe 23 Working from both sides remove the front fixing screws 24 together with the washers Bodywork TUAREG 660 BODYW 296 ...

Page 297: ...dicated and disconnect the connector of the fuel level sensor Remove the fuel tank In order to remove the fuel level sensor After unscrewing the four fixing screws extract the fuel level sensor 25 TUAREG 660 Bodywork BODYW 297 ...

Page 298: ... proceed as described Unscrew and remove the ring nut 29 of the fuel pump Remove the fuel pump 30 complete with seal To perform the reassembly and installation of the fuel tank carry out the procedure descri bed previously for removal in reverse order USE NEW METALLIC CLAMPS DURING REASSEMBLY Bodywork TUAREG 660 BODYW 298 ...

Page 299: ...that make up the side tail fairings including the side panels and the li cense plate holder Then proceed as described Disconnect the fuse boxes 1 from the mounts Remove the cable guide 2 by discon necting main cable harness Remove the two lower screws 3 tak ing care to recover the T bushes Remove the rear screw 4 TUAREG 660 Bodywork BODYW 299 ...

Page 300: ...8 from the cable guides 7 Front mudguard To remove the front mudguard follow the proce dure described below Unscrew the fixing screw of the cable guide that fastens the brake line to the mudguard Working on both sides remove the fas tener screws of the front mudguard to the stanchions Bodywork TUAREG 660 BODYW 300 ...

Page 301: ...AY ATTENTION TO THE PIN ON THE REFLECTOR THAT MUST BE INSERTED IN THE CORRESPONDING HOLE ON THE MUDGUARD To assemble the front mudguard carry out the procedure described above in reverse order Instrument cluster cover To remove the instrument panel cover after re moving the windscreen proceed as follows Remove the four fixing screws TUAREG 660 Bodywork BODYW 301 ...

Page 302: ...en To remove the windscreen follow the procedure described below Remove the four fixing screws paying attention to collect the bushes posi tioned on the support Remove the complete windscreen Remove the four bushes Bodywork TUAREG 660 BODYW 302 ...

Page 303: ...t panel support it is nec essary to first remove the front fairing complete with the light unit the side fairings air ducts and the instrument panel Then proceed as described Remove the five connection screws 1 of the instrument panel support Remove the two screws 2 that fasten the right instrument panel support to the chassis TUAREG 660 Bodywork BODYW 303 ...

Page 304: ...onnector 5 of the ambient temperature sensor to remove the right instrument panel sup port Disconnect all the connectors to com pletely free the left support 6 and the instrument panel support 7 Unscrew the three screws 8 securing the expansion tank to the left instru ment panel Bodywork TUAREG 660 BODYW 304 ...

Page 305: ... nesses CENTRAL INSTRUMENT PANEL SUPPORT It is possible to remove the central instrument pan el support without having to remove the side sup ports To carry out this operation proceed as described Remove the windscreen instrument panel and instrument panel visor to dis connect the connectors attached to the central instrument panel support Unscrew the four fixing screws and re move the central ins...

Page 306: ...itch is turned to OFF Remove the saddle Undo the two screws 1 and remove the battery cover 2 Unscrew and remove the screw 3 from the negative terminal Move the negative lead 4 aside Unscrew and remove the screw 5 of the positive terminal Move the positive lead 6 aside TAKE UTMOST CAR AND DO NOT MAKE CONTACT BE TWEEN THE BATTERY TERMINALS AND ANY METALLIC OBJECT IN ORDER TO PREVENT THE RISK OF SHOR...

Page 307: ... 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 fairing remove the saddle and licence plate holder Then proceed as described THE FOLLOWING OPERATIONS REFER TO ONE SIDE BUT ARE VALID FOR BOTH Remove the four side screws 1 After disconnecting the pin towar...

Page 308: ... 4 located under the tail fairing On both sides of the vehicle remove the side fixing screws 5 of the tail fair ing Remove the three upper fixing screws 6 of the tail fairing Remove the tail fairing complete with the rear light cluster Bodywork TUAREG 660 BODYW 308 ...

Page 309: ...ctors To remove the air ducts it is first necessary to re move the fuel tank cover Then proceed as descri bed Working on both sides remove the two fastening clips of the air ducts Disconnect the pin of the air duct from the tank Slide off the front part of the air duct to remove it TUAREG 660 Bodywork BODYW 309 ...

Page 310: ...255 256 C Chain 25 191 199 204 D Drive chain 25 199 E Electrical system 13 25 58 Engine oil 38 F Fairings 289 Fork 132 134 137 139 Front wheel 165 Fuel 127 293 Fuel pump 127 Fuses 118 H Handlebar 130 Headlight 55 282 283 I Identification 23 Instrument panel 282 K Keys 110 L License plate holder 291 Linkages 160 M Maintenance 20 36 ...

Page 311: ...9 306 Rear wheel 173 Recommended products 37 S Scheduled maintenance 36 Shock absorbers 156 Side fairings 289 Side stand 219 Spark plug 37 Stand 219 T Tank 271 293 Throttle body 42 46 Transmission 24 Turn indicators 284 Tyres 27 U Use W Wiring diagram 108 ...

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