I am one of the people on ADVrider who posted about this problem. A couple guys did email ApriliaUSA and got no where. Basically, the corporate response is to ignore the issue because most people will never open their forks because most won't go off-road and won't realize they have a problem. I switched my progressive springs to linear, increased the spring rate (I weigh 80kg), and had the bent shims replaced and the shop added a taller space to prevent the cupping problem.
Im the same weight. Would be interested to hear what parts you went with 😊. .. and how the bike feels? I pinned the comment as this needs to be seen by everyone.
I contacted Aprilia us and have an email chain with a rep that "seemed" to say they will cover it under warranty at only an Aprilia dealer. They hate to admit it but they know all about it. I do not trust any Aprilia dealer to make this fix.
@@PatchedBandit My suspension guy install K-Tech springs. Part # 38-425-60 These are for a Yamaha and are a few mm shorter than the OEM springs. He fabricated an adapter/spacer to fill in the gap. The bikes rides higher in the stroke and does not dive half as much as the progressives allowed on hard braking. I have never bottomed out, so I do not miss the few mm I sacrificed. Both on road and off road handling are greatly improved.
UPDATE 10/07/2024: Fist 2024 bikes are getting opened and they have the same issue according to advrider forum. Unfortunately it looks like even though the issue is known by Aprilia nothing is being done about this. Every single owner on that forum thread that has opened the forks find the same assembly mistake in there all the way through years 2022, 2023, 2024.
@@PatchedBanditWow. I can’t believe they still have not fixed this, mine is a 2023. I would be interested in the cost of having yours repaired. Can you give us an idea? I am thinking about having mine looked at. Thanks again for this video!
Watching that dude work slowly and precise was a true pleasure 👍 and again Aprillia have a big problem on their hands, which is a shame because they do build great bikes but there is allways just that little thing to concern people
Great video. I did my own repairs and upgraded the stock base valve (check valve) with a high speed base valve from EVO Oregon in the compression leg. I also installed 0.6 linear springs. The bike is so much better now. My shims were completely cracked. I had a crash on the ORBDR last year where I went through the front screen and broke the stock dash tower. My gut tells me that this was partly due to the messed up front suspension. So if you're listening @Piaggio: This is a safety issue and people could get hurt! Sounds expensive!
@@ricklee4122 , my front suspension worked great when the bike was new, but over time got harsh when hitting bumps in the road or rocks and dips on the trail. After replacement of the damaged shims and flipping the piston 180* plus the installation of the EVO base valve, the suspension is great. The forks absorb everything I throw at it and feel better than when the bike was new.
Felt this a couple weeks ago on my 2023. Was going down a dirt ride with some speed and hit a lot hole and it felt like I had no suspension through it. Most of the force was transferred to my hands and wrists. Scared me for a minute, but at least now I know what the issue is!
Thanks for commenting. Every comment helps to better understand the problem scale. Unfortunately from the information here and ADV rider forum it looks like every bike is affected and even worse nothing is being done to this from the manufacturer side. Even 2024 bikes have been reported.
@@PatchedBandit can we tag Aprilia here somehow? Maybe we should share around their contact details to make it easy for everyone to reach out. It really is a warranty issue.
Excellent video with both good information and filming. If this is a common problem with the Touaregs, you might consider getting enough people together to file a "class action" suit. My guess, just a threat to do that, will make Aprillia wake up and maybe offer a service. They can probably in return turn to KYB for compensation. But keep doing videos like this for other common service problems. That will get you subscribers.
Aprilia should definitely come forward with this. Minor issue but very annoying that they just keep quiet about it. Sweeping things like this under the rug will alienate customers.
Hi! First of all, very good and informative video, best i have seen about Tuareg forks. I have 23 Tuareg and had the same issue, valve was upside down, shims were bent and all blue, burnt oil had clogged oil passages and oil itself was totally black. Here in Estonia dealer didnt know anything about it, at least thats what they said.
thank you it was really informative and quite awesome to see all the engineery that goes inside a fork (congrats for Timo for mastering all this). Not having a Tuareg (I ride a 800DE) I can't help you getting a racing fork :D or telling if I have a faulty Kayaba ;) It's quite concerning that such a renowned brand has QC problems. :/
Great video. I have seen some posts on this problem. It's quite possible every bike has this issue, it just might not be felt by all riders. Aprilia should do a recall to address this issue but how do we get them to do it? It would be nearly impossible to get a dealership to tesr down a fork to ide tify a shim stack issue. I will be keeping a close on how my bike performs,,, once I get it back.
Thanks! I don't think there is much customers can do other than ask about it from their closest dealer and make a bit of fuss to get this sorted. I wanted to make this video to raise awareness to all the owners to at least have the knowledge about the issue. I hope the video reaches a lot of riders out there and helps some of them.
@@PatchedBandit Mine were ripped with only 5% riding time on gravel roads! Sent the invoice for repairs with pictures to Piaggio North American 2 weeks ago, but they haven't responded.
I think it's also a problem with a lot of new riders like me (hopefully I can pick up my new Tuareg this week) that have no previous off road experience to compare how it should feel. Also it will be very hard to be in a situation where you're able to compare other Tuareg's.
Mine was opened at 18700km, it had the same flaw, TTM fixed it. At the same time rear shock was opened and maintenance was done. Nothing was wrong in the rear shock.
My Aprilia rear shock had metal thread's in the blades. After 800km I just had spring function. Got a new on warrenty. And a workshop opened it up and said it was poor machining by kyb. New shock and it worked much better for 10.000km. Gonna get my front checked this winter. Have not noticed on normal riding. But poor damping in hard bumps. Awsome video. Best Regards viewer from Norway
Problem is they still dont have an official statement and/or instructions to local dealers. So its a case by case thing and no official callbacks so far either. Makes me suspect callbacks are not coming as this is already been happening through 3 different model years according to adv rider forum users.
it must be one of those random production issues, that I hope KYB is addressing internally - mine has been perfect, no problems. Glad to know it was an easy fix for you...i frikkin love my Tuareg - my 32nd bike. Just like you when you got it fixed!.....I am sooo looking forward to a full exhaust.....just to save a little weight and release even more luurvly sound!
Every single bike opened in advrider discussions have had this issue. All the way through model years 22, 23 and 24. This based on the forum discussion there that is already 40~ pages long. With high probability your bike has the same problem and if so it will get worse and worse over time. It is beneficial to get it fixed before parts of metal start scraping things in the tubes.
My Tuareg was a '22 Martian Red. I noticed the suspension not feeling right on washboard surface. Dealer in Denver Colorado said the piston was installed upside down on left fork leg, compression side. Warranty repair was approved.
@@ricklee4122 I did not have to pay and Imperial did the job in 2-3 days. As I recall, this was all at the 600 mile service. Compressing the fork did not feel right to me, I showed them, they agreed, no pushback or hassle at all. Imperial was wonderful.
I notice a patch of fork roughness/instability as I side-to-side under engine decel coming into roundabouts on my '24 Tuareg. I also feel a notch when compressing the front fork while sitting stationary. Tried another bike in the shop, and it also has this notch. Wonder if either of these are related to the issue you have shown here. Thanks to you + TTM for the info.
Such a pleasant thing that you have people who can be trusted to work out the kinks. Piaggio Corp needs to do better with communication and follow-up. Heck, fix it and improve the next batch.
I was considering buying an Aprilia Tuareg, but now I will wait until this issue is resolved. The suspension is one of the features that attracted me to the Tuareg; if it's faulty, then that's a problem.
Good thing about this is that its not expensive to get fixed. A couple of model year -24 bikes have already reported the same issue so looks like nothing is gonna get done about this as its already a third model year with the same problem.
Great information video. I'm about to open my 2022 Tuareg Forks, one leaking seal. I have never been happy about the performance of the forks. Sharp pot holes or small logs they kick back terribly. Actually they make ridding off road dangerous, as you cant trust your front end when ridding more (even a little) aggressively. Definitely should be covered under warranty, but I wouldn't waste my time here in Australia. The Aprilia dealer here is a complete ass. Also my Electronic screen draws current all the time and discharges the battery in 4-5days if you don't ride bike (charge battery) or disconnect the battery.
I didnt have the battery discharge issue on mine. Also most dealer workshops are not very educated in suspensions so I would also advice just biting the cost and taking it to someone who specialises in these things.
If this is a problem, it depends for the factory: how many riders? We all know that forums tend to make a lot of noise, yet it's mostly them who find out and make it public. The factories would rather prefer to sit it out. Hope that Aprilia will give you something for addressing the problem. Because they will work Kayaba for a rebound. Cheers, Günter/Nürnberg
True that bad noises are very loud. But also I havent found a single post here or on the forums of anyone opening theirs and finding a correctly put together forks. Starting to think this might be on all bikes…. Ofcourse this is just guessing.
As far as "making a lot of noise", not one person on ADVrider who has looked has found their forks do not have this problem. The count is approximately 25 out of 25 inspected all have the problem. VINs from early 2022 to end of 2023. No one with a 2024 has added to that thread as of yet. This is the 3rd RU-vidr who posted this issue.
I got a quote for a few hundred bucks for the fix at a private suspension shop. The dealership said they would have a look and try to warranty it with Aprilia. They couldn’t give a time estimate as they may have to order parts. So now I’m stuck deciding between the quicker but costly option or the most likely long and maybe cheaper option.
I decided to go with expertise. Specialized shops like the one on this video know exactly what they are doing and they get the job done quick with parts already in the shop.
On my 2023 Tuareg,I'm feelling insecure offroad,there are a very harsh suspension response ,unexpectable from a offroad oriented bike. I suspect the same problem.
maybe try to open compression damping more than recommended. I did this and it felt way better, The issue described here is a minor one with a less obvious effect than you describe. Start with opening compression damping completely, then half way and after that find the right settings for you. You will feel the right amount.
You can support my work for only €0.99/month Become a channel member here: ru-vid.com/show-UC6hGP2VIz2D_m4ZTpKGmLPAjoin - Early access to new videos - Loyalty badges - Custom Emojis in comments - Member perks on Discord
Good old TTM Factory, always ready to explain and help. Nice to hear that front is now working better and Tuareg starts to feel serious Tenere killer 🫡💪
That remains to be seen but yes the bike feels much nicer 😁 I do prefer riding this Tuareg. It is better balanced overall compared to the T7. Fits me like a tailored glove.
Ok, wow. Now this is very, very interesting information and a great video, a thousand thanks! I've read countless stories about those forks and I really have to do something about that on my bike too. Ja samaa suomeksi. Mä olen ajanut kaksipyöräisillä vuodesta 1990 lähtien mutta en ole koskaan ollut mikään jousituksen asiantuntija enkä ole kunnolla sisäistänyt säätöjen sun muiden merkitystä, olen vain sopeutunut ja sovittanut oman ajamiseni kulloisenkin vekottimen ominaisuuksille. Ja valtaosa omasta ajamisestani on kuitenkin asvalttipinnalta, tämä adventurepuoli on ollut lähinnä vuosien 1990-1992 ja 2021-present välistä harrastusta eli tavallaan ihan uutta juttua mulle. Muutama kesä takaperin Tuareg-toverillani oli eräällä reissullamme vuokralla KTM:n super adventure vai mikä olikaan, ja ajoin sillä yhden iltapäivälenkin. Ihastuin silloin sen keulaan ja hakemalla hain kaikki routapaakut ja muut kuopat ja möykyt huonokuntoisilla asvalttiteillä, joita silloin kurvailtiin, ihan vain sen takia että ne eivät tuntuneet kertakaikkiaan miltään. Ne vaan imeytyivät sinne jonnekin, pyörä vain liiteli kaiken yli. Odotin samaa kokemusta Tuaregin ostaessani kevättalvella 2022 mutta pieni pettymys olikin kun se ei ihan samalla tavalla reagoikaan töyssyihin. Kyllä ne Aprilialla tuntee ja huomaa. Voisikohan tuo sittenkin olla sieltä keulan rakenneongelmasta kiinni vai meneekö edelleen erilaisen pyörän ja jousituksen piikkiin. Saa nähdä, olen melko valmis viemään oman pyöräni TTM:lle huollettavaksi. Kiitos vielä loistavasta videosta :)
Super adventure ja iso GS ovat ihan eri vehkeitä. Ne todellakin piilottaa kraaterit allensa ja suorastaan leijuu kaiken yli. Ei näistä "keskikokoisista" adv pyöristä mikään ole mun käytössä siltä tuntunut, mutta jämäkkä ja tärisevä on silti ihan eri tuntemukset. Pyörän pitää tuntua siltä, että se pysyy tiessä vaikka tulee kuoppaa ja pattia vastaan. Alustaan pitää pystyä luottamaan 100 vauhdissa mutta myös 20 vauhdissa eikä se saa hakata käsille nimismiehenkiharassa niin että paikat irtoaa takahampaista. Tuareg on (toimiessaan) parempi, kun esim perusmallin Tenere 700. Asfaltilla tätä videolla korjattua ongelmaa ei tunne. Suosittelen tsekkaamaan keulan, kun se ei kovin kallistakaan ole. Todellakin sijoituksen arvonen homma ja samalla tulee tehtyä öljynvaihto mikä on aina hyvä juttu keulaputkille, joihin yleensä tyypit vaihtaa öljyjä ihan liian harvoin.
@@PatchedBandit se on täysin totta, mä sen olen myös tiedostanut että keulan öljyjen vaihto olisi kannattanut tehdä jo ekan vuoden jälkeen. Mulla tulee ihan just kymppitonni täyteen eli seuraavan huollon aika. Mutta noista kilometreistä voisin äkkiä sanoa että 6-7000 on tullut sorateillä ja pienillä poluilla. Olen koittanut onnistuneesti pysyä poissa kestopäällysteeltä tuolla vehkeellä.
@@PatchedBandit mun Indaco Tagelmust on pelittänyt mallikelpoisesti, ei minkäänlaista ongelmaa. Toverin Martian Red nyt onkin sit kiukutellut enemmänkin. Heti kärkeen oli se perinteinen startin löysä / hapettunut liitos ja hinurilla huoltoon. TET-reissulla hukkasi keulan yläkolmiosta sen ison mutterin ihan tosta vaan. Tällä hetkellä vilkuttaa iloisesti bensamittaria eli olikos se nyt sitten se anturivika.. Penkki "suli", tai jotain sille kävi, se on siitä munien kohdalta ihan jäätävässä tahmassa, ikäänkuin siinä olisi liimaa. Mutta mä tiesin jo netin ekoista prototyyppikuvista, että tuommoinen pitää saada, ja tuolla värillä, niin olihan se heti hankittava 350:n Tuaregin kaveriksi samalla värimaailmalla. En ole katunut hankintaa :)
I don't want to disclose pricing as it may vary over time and due to many other reasons. TTM Factory can give quotes themselves 😊 I did pay for the service though so this is not a sponsored video. I'm not after any compensation from the Aprilia dealer either for myself. I just wanted to make this video to raise awareness among owners. The service is not super expensive though as it's mostly just work and oils if no other parts are broken.
Thank you for the heads up and great vid. Im planning to buy a used 22 Tuareg in few days, it has around 10Km on it, is there a way to know if it has that problem by test driving it?
Try to get it serviced under warranty. But if they are difficult or don't have the needed knowledge this is not super expensive at a dedicated suspneison workshop.
I've got quite high stiction too. I've took it apart to investigate and rework. I figured out that all that stiction comes from SKF dual compound seals. No matter how well it is lubricated or if bearing grease is used instead of fork oil, it still keeps high stiction. The cause is not related to Rally Raid cartridge. The only possible fix is to replace seals with different brand. I haven't done that yet.
I hesitate on disclosing pricing as I’m not involved in the business and dont want everyone to assume it would always be the same. I suggest asking for a quote using this video as reference to what needs doing.
@@PatchedBandit thanks. I dont live in Finland but riding around europe with goal to go up to Talinn. So I was kinda curious to see if crossing the baltic could be worth it😅
Timo can give a quote through their website. Links in the description. Pricing is very modest considering the superior level of knowledge they have in my opinion. But they are BUSY so book well in advance.
I hesitate on disclosing pricing as I’m not involved in the business and dont want everyone to assume it would always be the same. I suggest asking for a quote using this video as reference what needs doing.
Most likely there has been a wrong assembly instruction on the assembly line itself. But this is me just guessing as I know nothing more about this than any other customer.
@@PatchedBandit I do know that KYB replied to an inquiry and said that the bent shims should not affect performance of the suspension. It is later in the thread on ADVrider.
@@briangc1972 Well thats a * answer. Cant use the right word as YT would just remove my comment. This would mean they are lying to save money. Not a good look.
Loved the attention to detail you put into this video. It was a joy to watch your suspension guy do his work. He is a master at his craft. I will definitely be getting my forks opened up before the warranty expires. I only wish I could take them to your guy instead of my local Aprilia dealer.
Thanks for posting this very in depth video of TTMs work on your forks!!! I have been following the Adv forum posts of what people were finding when taking apart the forks. Do you know if TTM flipped the piston (compression fork) from it's installed position, or left it in the same orientation as it was installed? I was looking at the before and after in your video and couldn't tell for sure. If you read the Extravaganza post on ADV Rider that was a point of discussion (what is or was the intended design). Also what Shim stack to use. The V1 vs V2 version from Bikedude987. I have a new to me 2023 660 still below the 621 mile break in (US). Feeling similar fork response to what people are posting.
Pretty sure the piston was also flipped but as making a step by step tutorial would have taken the whole day this wasn't the main purpose of the video unfortunately. I was allowed to film but that was pretty much it 😅 At 5:20 you can see how it was assembled in the factory. 8:07 is where you can see the piston going back in place.
I checked the film again and took screenshots. You can actually see the piston flipped here. I posted pics for you to see: drive.google.com/drive/folders/1bOypFrDlJMJe6I9FnK7h2RpM3THV6RkB?usp=drive_link
@@PatchedBandit thank you very much for posting this important information. I am about to purchase a 2024 Tuareg 660 and I will be using it for off-road riding as much as on-road. Great work!👍
Wow, that is a nice suspension shop - think I even saw a shock dyno in the back corner. I took the forks apart on my '22 per the ADVrider forum and found the piston was installed backwards and allow the shim deformation in the compression side. I got lucky - the rebound side shims were ok - wish I had the shorter bypass sleeve, but just reassembled being careful to keep the shims off of the threads when tightening. On the compression side, I flipped the piston so the bypass sleeve now fit into its groove and replaced the bent shims and installed the custom compression base valve from EVO Oregon. Fork feel is very plush now, but I'm thinking that a non-progressive front spring might be better as the initial suspension feels a little soft.
The more I look into this bike that I wanted to purchase, the more problems I keep finding. I guess i'm just gonna have to stick with a japanese manufacturer.
Italian bikes will always come with some issues. Good thing is that there is still nothing crucial being reported about these but lot's of minor annoyances like this. I wish the Japanese bikes would be as good as the Tuareg to ride but they are not.
Great video, thanks!!! What year is your Tuareg? Do you think it would be only certain years/batch or all Tuaregs? Just asking because I have a 2023 model purchased Nov 23.
All the bikes on ADVrider that were opened up had the deformed shims, the range was from early 2022 to 2024. It is a very good guess that this affects all bikes delivered.
I am for sure interested in a possible custom build, if you get into that. Would be nice to have Ti nitride barrels if that's an option. I'd lean more towards a linear spring, and I was reading it's hard to find them sized for the stock barrels.
I have not asked for any comment from Aprilia myself. I have informed my dealer about this and they see the video too. As this is not a brand new finding I don’t think there is going to be any official callback about this issue. First post on ADV rider about this was way back in ”Bikedude987, Feb 9, 2023”. But the problem is not just a couple of bikes.. clearly.
@@PatchedBandit Piaggio North America knows about the problem but they aren't doing anything about it. I've talked to 3 reps about this and sent pictures of my ripped shims with invoice for the repair 2 weeks ago with no response.
I think it's an issue of the older models... 24 onwards seems to be OK... Haven't seen any people with newer models reporting it so let's hope it's ok now!
Hyvä täsmennys ettei ongelma ollut Aprilian puolelta tullut 👍 . Tosin asiasta vielä vähän mielenkiintoisemmaksi tekee se, että pyöräthän käy siinä ensihuollossa, ja ihmeesti siinä ei paljoa välitetä itse pyörän kokonaistoiminnasta kuitenkaan 🤔 . Josta tosiaan videon lopussa mainitsitkin 😀.
Jälleenmyyjäthän on vähän valitettavassa välikädessä, jos valmistajalta ei tule virallista tiedotetta että tällaista ongelmaa on. KYB on todennäköisesti möhlinyt kasauksen omassa päässä ja myynyt putkia ison läjän tällä tavoin väärin kasattuna. Olis asiallista, jos asia huollossa tarkastettais ja korjattais valmistajan piikkiin. Mutta nää on hankalia keissejä varmasti. Jälleenmyyjiä tästä ei tietysti voi syyttää.
@@PatchedBandit kyllä hyvin asiaa täsmensit vielä lisää ja totesit myös videonkin lopussa näitä seikkoja, jonka huomiona vielä lisäsin itsekin omaankin kommentointiini. Asioissa on tosiaankin niin useita tekijöitä, ja kun vika on yhden komponenttivalmistajan, niin kukaan ei toki haluaisi ottaa siitä aiheutuvia kustannuksia omille harteilleen kovin helposti. Harmi vain tällaiset jutut itse tuotteen ja niiden omistajien puolesta. Tuotat muutoin laadukasta materiaalia englanniksi 👍 .
interesting, another reason not to like split fork systems, and I have always been a Kayaba man, the whole concept of one fork for compression and one for rebound damping is just totally flawed for me, and puts undue stress on both forks, not sure if or when i will get around to that video, but if i do is it ok to use some clips and show your example of the inherent problem with that approach? ill credit you of course, Ride Free my friend,
I agree engineering wise it just worse design for sake of some ease of tune. I do hate to get low to adjust compression on my AT forks but I still prefer that to split
@@Angry-Lynx its been an interesting split of opinion on this one, but the balance agrees with you from my viewers, its probably running about 70/30% against and for the split system
