APRILIA Tuono 660 2021 Guide

SERVICE STATION MANUAL

2Q000453

RS 660 - Tuono 660

SERVICE STATION

MANUAL

RS 660 - Tuono 660

THE VALUE OF SERVICE

Due to continuous updates and technical training programmes specific to aprilia products, only Aprilia

Official Network mechanics know this vehicle fully and have the specific tools necessary to carry out

maintenance and repair operations correctly.

Thereliabilityofthevehiclealsodependsonitsmechanicalconditions.Checkingthevehiclebeforeriding

it, performing maintenance correctly and using only original Aprilia spare parts are essential factors

for the reliability of your vehicle!

For information on the nearest Official Dealer and/or Service Centre consult our website:

www.aprilia.com

Only by requesting original aprilia spare parts can you be of purchasing products that were developed

andtested duringthe designand developmentof thevehicle itself.All Apriliaoriginal spareparts 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 beforehand,

to make any changes to components, parts or accessory supplies which it deems necessary to improve

the product, or which are required for manufacturing or commercial reasons.

Notallversions/modelsshowninthispublicationareavailableinallcountries.Theavailabilityofindividual

versions/models should be confirmed with the official Aprilia sales network.

The Aprilia trademark is the property of Piaggio & C. S.p.A.

in part is prohibited.

Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy

www.piaggio.com

SERVICE STATION MANUAL

RS 660 - Tuono 660

This manual provides the main information to carry out regular maintenance operations on your vehicle.

This manual is intended to Aprilia Dealers and their qualified mechanics; several concepts have been

deliberately omitted as they are considered unnecessary. As it is not possible to include complete

mechanical notions in this manual, users should have basic mechanical knowledge or minimum

knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or

checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures

are not described in detail, be extremely cautious so as not to damage components or injure individuals.

In order to optimise customer satisfaction when using our vehicles, Piaggio & C. S.p.a. commits itself

to continually improve its products and the relative documentation. The main technical modifications and

changes in repair procedures are communicated to all Aprilia Sales Outlets and its International

Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of

need or further queries on repair and check procedures, consult Aprilia CUSTOMER DEPARTMENT,

which will be prepared to provide any information on the subject and any further communications on

updates and technical changes related to the vehicle.

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sectionsmarked with this symbol indicate the correctuse of thevehicle

to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious

damage to the vehicle and sometimes even the invalidity of the guarantee

INDEX OF TOPICS

PRE-DELIVERY PRE DE

CHARACTERISTICS CHAR

SPECIAL TOOLS S-TOOLS

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE ENG

POWER SUPPLY P SUPP

SUSPENSIONS SUSP

CHASSIS CHAS

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

BODYWORK BODYW

INDEX OF TOPICS

PRE-DELIVERY PRE DE

Aesthetic inspection

- Paintwork

- Fitting of Plastic Parts

- Scratches

- Dirt

Tightening torques inspection

- Safety fasteners:

front and rear suspension unit

front and rear brake calliper retainer unit

front and rear wheel unit

engine - chassis retainers

steering assembly

- Plastic parts fixing screws

Electrical system

- Main switch

- Headlamps: high beam lights, low beam lights, taillights (front and rear) and relevant warning lights

- Headlight adjustment according to regulations in force

- Rear brake light push-button

- Turn indicators and their warning lights

- Instrument cluster

- Instrument cluster warning lights

- Horn

- Electric starter

- Engine stop via emergency stop switch and side stand

- Through the diagnostic tool, check that the last mapping version is present in the control unit/s and,

if required, program the control unit/s again: consult the technical service website to know about avail-

able upgrades and details regarding the operation.

CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

THE LACK OF AN ADEQUATE BATTERY CHARGE BEFORE THE FIRST USE WILL CAUSE A

PREMATURE FAILURE OF THE BATTERY.

CAUTION

RS 660 - Tuono 660 Pre-delivery

PRE DE - 7

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-

ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. THE USE OF A

FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE-

HICLE OR EVEN CAUSE A FIRE.

- Check the battery charge by holding down the

TEST button on the BATTERY CAPACITY INDI-

CATOR located between the terminals on the top

of the battery.

Depending on the present indication and consult-

ing the table, if necessary charge the battery.

CHARGE LEVEL

ACTION NUMBER OF BARS

Ready for use 5 - 6

Charging recommended 3 - 4

Charging necessary 1 - 2

Fault 0

RECHARGE

- Always use a specific charger for lithium batteries to recharge the battery.

- To avoid damage to the battery, the charging voltage must NEVER be higher than 15 volts.

- Do not charge the battery with a charger with automatic DESULPHATION MODE using a voltage

higher than 15 volts.

- Always remove the battery from the vehicle before connecting it to the charger.

-Stopcharging if thebatteryfeels warmtothetouch. Allowthebatteryto coolbeforeresumingcharging.

- After recharging the battery, leave it to stand for 1 hour before pressing the TEST button on the

BATTERY CAPACITY INDICATOR. If the indicator is between 1 and 4 notches, the battery should be

further charged.

CHARGE MODES

Normal recharge

- Electric current: 2,0 A

- Time: 2 hours

Quick charge

- Electric current: 8 A

- Time: 0,5 hours

WARNING

THE CHARGE VOLTAGE MUST NEVER EXCEED 15V.

WARNINGS

Pre-delivery RS 660 - Tuono 660

PRE DE - 8

- Do not knock, throw or subject the battery to violent shocks.

- Do not carry the battery together with flammable, explosive or sharp objects.

- NEVER attempt to open the battery.

- Keep the connecting poles clean and firmly secured at all times.

- Do not immerse the battery in water, or leave it exposed to moisture.

- Do not connect the battery directly to wall outlets.

- Do not subject the battery to short circuit by connecting cables or other metallic objects to the positive

and negative terminals.

- Do not pierce the battery casing with nails or other sharp objects, do not try to forcibly open it or step

on it.

- Do not perform welds on the battery terminals.

- Do not use the battery in combination with primary batteries (such as dry batteries) or batteries of

different capacity, type and brand.

-Donotusethebatteryifitemitsastrangeodour,emitsheat,changescolouror deforms, or ifit presents

any anomaly. Stop use immediately if the battery is in use or under charge.

THE BATTERY DOES NOT CONTAIN HARMFUL POLLUTANTS, CORROSIVE ACIDS OR TOXIC

HEAVY METALS

(IF AVAILABLE)

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 the container to

break the seals. The liquid will begin to

flow into the cells.

RS 660 - Tuono 660 Pre-delivery

PRE DE - 9

•Check that air bubbles come out of the

cells; let the liquid flow into the cells for

at least 20 minutes.

•If no air bubbles escape and the liquid

does not flow, tap lightly on the bottom

of the container until the liquid begins

to flow into the cells. Never remove the

container from the battery, pierce it or

cut it to facilitate the exit of the liquid.

•Make sure the liquid container is com-

pletely empty before removing it.

•Allow the battery to stand for at least 1

hour,beforestartingthe chargingproc-

ess, without closing the six cells. This

operation is extremely important in or-

der to have the best battery perform-

ance over time.

•Recharge the battery following the

specifications indicated on the battery

(see photo ) and using a suitable bat-

tery charger.

NOTE

IN THE SHOWN EXAMPLE IT IS IMPORTANT TO USE A

BATTERYCHARGERWITH1.2AMPERE (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

Pre-delivery RS 660 - Tuono 660

PRE DE - 10

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