Aprilia Tuareg 660 Rally suspension testing, development and upgrade recommendations
Aprilia Tuareg 660 Rally – Suspension Review & Development
The Aprilia Tuareg 660 Rally is positioned as the more off-road-focused version of the standard Tuareg, so we wanted to find out how much had actually changed beneath the surface.
As with all of our Featured Bike development, we started with the bike as delivered: measuring sag, riding it in standard trim, inspecting the suspension hardware and then stripping and testing the components before developing any modifications.
The Rally is a well-presented bike with plenty of useful rider electronics, including adjustable traction control, ABS and throttle maps. Our main concern was the suspension. Initial testing found the bike very soft, with noticeable wallow and excessive brake dive.
Aprilia Tuareg Rally Forks
The Rally uses 43mm KYB split open-cartridge forks, with compression adjustment in one leg, rebound in the other and preload adjustment in both. Aprilia has also made an important change from the standard Tuareg by fitting 6.2 N/mm linear fork springs rather than the progressive arrangement used previously.
That is a better starting point, particularly for riders using the bike off-road.
However, after evaluating the forks we still found significant scope for improvement in chassis support and control. The Rally may carry different branding and a more off-road-focused specification, but it has not eliminated the suspension limitations we identified during our development work on the standard Tuareg.
We therefore developed a dedicated Teknik fork upgrade for the Tuareg Rally.
The Rally kit shares much of its design philosophy and component architecture with our proven standard Tuareg solution, but it has been validated specifically on the Rally and is supplied as its own application and SKU. This allows us to treat the two models separately rather than simply assuming that what works in one should automatically be carried across to the other.
Testing with the Rally-specific setup produced the improvement in control and support we were looking for while retaining the standard Rally springs during development.
For most Rally owners, the fork kit is our first recommended suspension upgrade. Spring rate can then be selected around rider weight, luggage and intended use where required.
Aprilia Tuareg Rally Shock
The rear shock is a 40mm monotube design with a piggyback bladder and hydraulic preload adjustment, broadly similar to the type of shock used on the standard Tuareg, earlier Tenere 700 and Ducati DesertX.
Compared with the forks, the rear of the Rally gives us a more workable starting point.
The standard spring is 82 N/mm, which we consider suitable for a reasonable percentage of Australian riders. Heavier riders, passengers or bikes carrying substantial luggage may still benefit from a spring change, but it is not an automatic requirement.
Our development work focused on improving the shock's control and adjustability rather than simply replacing the entire unit. Revised internal components, rebound separation and an upgraded compression adjuster produced worthwhile results during testing. A heavier Eibach spring was also fitted to the development bike to suit its rider.
This gives Rally owners several levels of upgrade depending on rider weight, load and how aggressively the bike is being used.
Is the Rally Better Than the Standard Tuareg?
Yes — but it can be better again.
The most useful suspension change from Aprilia is the move to a linear fork spring, giving the Rally a better foundation than the standard bike. The basic behaviour we experienced during testing, however, was still familiar: excessive movement under braking and a loose, wallowing feel when the suspension was asked to work harder.
Our engineering assessment was that the Rally represents an improvement over the standard Tuareg, but not a major step forward in suspension performance.
That is also why we have treated the Rally as its own development application. The solutions are closely related to those we developed for the standard Tuareg, but the Rally receives its own tested specification rather than simply being grouped under the existing model.
Our Recommended Upgrade Path
For riders using the Tuareg Rally for genuine adventure and off-road riding, we would start with the Teknik Tuareg Rally fork upgrade kit. It addresses the area where we found the greatest opportunity for improvement while retaining the good aspects of Aprilia's revised Rally spring specification.
From there, spring selection should be matched to rider weight and load. For riders looking for greater rear-end control, the standard shock can also be upgraded with revised damping components and improved adjustment.
The Tuareg Rally is a capable platform and Aprilia has made some sensible changes over the standard bike. Our testing simply shows that there is still plenty available from the suspension once the setup is developed around how the bike is actually being ridden.
