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.
© Copyright 2021 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
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
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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
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•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