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APRILIA RS 660 User Manual

APRILIA RS 660
420 pages
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SERVICE STATION MANUAL
2Q000453
RS 660 - Tuono 660

Table of Contents

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APRILIA RS 660 Specifications

General IconGeneral
Displacement659 cc
Bore x Stroke81 mm x 63.93 mm
Compression Ratio13.5:1
Maximum Power100 HP (73.5 kW) @ 10, 500 rpm
Maximum Torque67 Nm @ 8, 500 rpm
Transmission6-speed
FrameAluminum dual beam chassis
Front Tire120/70 ZR 17
Rear Tire180/55 ZR 17
Seat Height820 mm
Dry Weight169 kg
Wet Weight183 kg
Engine TypeParallel twin
Fuel SystemElectronic fuel injection with 48 mm throttle bodies
Front SuspensionKayaba 41 mm upside-down fork, adjustable rebound and preload
Rear SuspensionKayaba monoshock, adjustable rebound and preload
Front BrakeDual 320 mm discs, Brembo radial calipers
Rear Brake220 mm disc, Brembo caliper
ABSCornering ABS
Fuel Capacity15 liters
ElectronicsRide-by-wire, multiple riding modes, traction control

Summary

Rules

Safety rules

General safety guidelines for handling chemicals, hot parts, and emissions.

Characteristics

Engine Specifications

Detailed technical data for the engine, including capacity, bore, stroke, and valve clearances.

Tightening Torques

General and specific torque values for various fasteners and components.

Special Tools

Crankshaft and Flywheel Tools

Tools for flywheel side crankshaft locking, water pump seal insertion, and crankshaft support.

Diagnostic and Measurement Tools

Tools for vehicle diagnostics, data reading, and suspension adjustments.

MAINTENANCE

Scheduled Maintenance Table

Intervals and required service operations for regular maintenance based on mileage and time.

Engine Oil Check and Replacement

Steps to check engine oil level when the engine is warm, and procedures for draining and replacing oil.

Valve Clearance Check and Adjustment

Procedure for checking and adjusting valve clearance using feeler gauges and calibrated pads.

ELECTRICAL SYSTEM

Electrical System Installation

Guidance on routing and fixing the vehicle wiring harness to the chassis and components.

ABS Control Unit Connector Procedure

Step-by-step guide for correctly fitting the ABS control unit connector, ensuring proper engagement.

Fuse Inspection and Replacement

Procedures for checking and replacing auxiliary and main fuses to troubleshoot electrical issues.

ENGINE

Gearbox Disassembly

Step-by-step instructions for disassembling the gearbox, including shaft and drum removal.

Starter Motor Removal and Installation

Steps for removing and installing the starter motor, including control unit and support removal.

Clutch Assembly and Disassembly

Detailed steps for disassembling and assembling the clutch, including plates, springs, and hub.

Crankshaft and Connecting Rod Checks

Procedures for checking crankshaft axial and radial play, and connecting rod wear limits.

Piston-Cylinder Coupling Inspection

Guidelines for inspecting piston diameter, aperture tolerance, and gap between piston rings.

Head and Valves Maintenance

Procedures for removing and installing the head cover, valves, bucket tappets, and calibrated pads.

Camshaft Timing Procedure

Detailed instructions for setting engine camshaft timing using specific tools and alignment marks.

Crankcase Splitting and Assembly

Steps for splitting and assembling the crankcase halves, ensuring correct lubrication and torque.

SUSPENSIONS

Front Fork Removal and Disassembly

Steps for removing and disassembling the front fork stanchions, including draining oil and checking components.

Front Fork Reassembly and Filling

Procedures for reassembling the front fork, inserting seals, springs, and filling with oil.

Shock Absorber Removal and Installation

Steps for removing and installing the rear shock absorber, including spring pre-load and rebound damping adjustment.

CHASSIS

Front Wheel Removal and Installation

Procedures for removing and installing the front wheel, including brake callipers, discs, and bearings.

Rear Wheel Removal and Installation

Steps for removing and installing the rear wheel, sprocket support, chain, and flexible coupling inserts.

Swinging Arm Removal and Installation

Procedures for removing and installing the swinging arm, including pivot bolt, footrest support, and shock absorber.

BRAKING SYSTEM

ABS System Operation and Levels

Explanation of ABS operation, intervention levels, and warning lamp indications for rider safety.

Bleeding the Braking System

Step-by-step guide for bleeding front and rear hydraulic brake systems to remove air.

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