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APRILIA STRADA 660 Service Manual

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INTRODUCTION
MY 660
INTRODUCTION
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Summary of Contents for APRILIA STRADA 660

  • Page 1 INTRODUCTION MY 660 INTRODUCTION 0 - 1...
  • Page 2 INTRODUCTION MY 660 SUMMARY INTRODUCTION .............................. 3 0.1.1 FOREWORD ............................. 3 0.1.2 REFERENCE MANUALS .......................... 4 0.1.3 ABBREVIATIONS/SYMBOLS/CONVENTIONS ..................5 0 - 2...

  • Page 3: Introduction

    manual.

  • Page 4: Reference Manuals

    INTRODUCTION MY 660 0.1.2 REFERENCE MANUALS OWNER'S MANUALS aprilia part# (description) 8104896 8104895 8104897 8104894 CHASSIS WORKSHOP MANUAL aprilia part# (description) 8140874 8140877 8140875 8140876 8140878 ENGINE TECHNICAL MANUAL aprilia part# (description) 8140880 8140883 8140881 8140882 8140884 CD FOR THE NETWORK - ENGINE...

  • Page 5: Abbreviations/Symbols/Conventions

    INTRODUCTION MY 660 0.1.3 ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ±...
  • Page 6 INTRODUCTION MY 660 RIGHT SIDE = right side = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork = volt...
  • Page 7 GENERAL INFORMATION MY 660 GENERAL INFORMATION 1 - 1...

  • Page 8: Table Of Contents

    GENERAL INFORMATION MY 660 SUMMARY 1.1. STRUCTURE OF THE MANUAL........................3 1.1.1. CONVENTIONS USED IN THE MANUAL ....................3 1.1.2. SAFETY WARNINGS ..........................4 1.2. GENERAL RULES............................5 1.2.1. BASIC SAFETY RULES ..........................5 1.3. DANGEROUS ELEMENTS..........................8 1.3.1. WARNINGS ............................... 8 1.4.

  • Page 9: Structure Of The Manual

    GENERAL INFORMATION MY 660 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual. •...

  • Page 10: Safety Warnings

    GENERAL INFORMATION MY 660 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.

  • Page 11: General Rules

    GENERAL INFORMATION MY 660 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room. Avoid starting the engine indoors. In case you are working indoors, use a gas exhaust system.
  • Page 12 GENERAL INFORMATION MY 660 DANGER Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce invisible flames. Wear latex gloves when servicing. Although toxic, it has a sweet taste that might attract animals. Never leave coolant in open container or in a position easily reachable by animals.
  • Page 13 NOTE All bearings must rotate freely with no hard spots or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 14: Dangerous Elements

    GENERAL INFORMATION MY 660 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and any element that could ignite fuel or provoke explosions.
  • Page 15 GENERAL INFORMATION MY 660 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.
  • Page 16 GENERAL INFORMATION MY 660 COOLANT DANGER Coolant is toxic when ingested, contact with eyes or skin may cause irritation. In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately.
  • Page 17 GENERAL INFORMATION MY 660 TYRES WARNING If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride. In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired. Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle. In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.

  • Page 18: Running-In

    After the first 1000 km (621 mi), have the checking operations indicated in the column "After running- in" carried out by an aprilia Authorised Dealer, see REGULAR SERVICE INTERVALS CHART, in order to avoid hurting yourself or other people and/or damaging the vehicle.
  • Page 19 GENERAL TECHNICAL INFORMATION MY 660 GENERAL TECHNICAL INFORMATION 2 - 1...
  • Page 20 GENERAL TECHNICAL INFORMATION MY 660 SUMMARY 2.1. TECHNICAL INFORMATION..........................3 2.1.1. TECHNICAL DATA............................ 3 2.1.2. LUBRICANT TABLE ..........................5 2.1.3. TIGHTENING TORQUE SETTINGS ......................6 2.1.4. SPECIAL TOOLS ............................8 2 - 2...

  • Page 21: Technical Information

    GENERAL TECHNICAL INFORMATION MY 660 2.1. TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA ENGINE Model MY660 Type Single-cylinder, 4 strokes with 4 valves and one overhead camshaft Number of cylinders Total displacement 660 cu. cm (40.27 cu in). Max. rated power (at the crankshaft) 35 Kw (47 HP) at 6250 rpm Max.
  • Page 22 GENERAL TECHNICAL INFORMATION MY 660 TRANSMISSION SYSTEM Gear ratios Ratio Primary Secondary Final ratio Total ratio 36/75 = 1: 2.083 12/30 = 1: 2.267 15/44 = 1: 2.933 15.278 16/26 = 1: 1.632 9.930 20/23 = 1: 1.300 7.028 22/20 = 1: 1.091 5.556 26/20 = 1: 0.960 4.700...

  • Page 23: Lubricant Table

    GENERAL TECHNICAL INFORMATION MY 660 2.1.2. LUBRICANT TABLE LUBRICANT PRODUCT RECOMMENDED: EXTRARIDE 4, SAE 15W – 50. Engine oil As an alternative to recommended oils, top brand oils meeting or exceeding CCMC G-4, A.P.I. SG specifications can be used. RECOMMENDED: F.A.

  • Page 24: Tightening Torque Settings

    GENERAL TECHNICAL INFORMATION MY 660 2.1.3. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 25 GENERAL TECHNICAL INFORMATION MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 - 1.5 Valve cover and timing cover screws 0.8 - 1.2 Oil channel hose screws 1 1.6 - 2.0 Spark plug 1.0 - 1.5 Oil channel hose screws 2 1.7 - 2.3 Oil channel hose side screw 2 0.8 - 1.2...

  • Page 26: Special Tools

    GENERAL TECHNICAL INFORMATION MY 660 2.1.4. SPECIAL TOOLS In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used. The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised methods.
  • Page 27 GENERAL TECHNICAL INFORMATION MY 660 Pos. Description Part number Flywheel puller 8140837 Flywheel rotor locking tool 8140838 Engine support plate 8140839 Crankshaft spacer 8140845 Crankshaft adapter 8140844 Water pump installing tool 8140841 Crankshaft installing tool 8140846 Crankshaft installing tool 8140847 Rocker arm shaft puller weight 8140849 Rocker arm shaft puller...
  • Page 28 ENGINE MY 660 ENGINE 3 - 1...
  • Page 29 ENGINE MY 660 SUMMARY 3.1. ENGINE ACCESSORIES ..........................3 3.1.1. REMOVAL ..............................3 3.1.2. TIGHTENING TORQUE SETTINGS ......................7 3.2. WATER PUMP..............................9 3.2.1. REMOVAL ..............................9 3.2.2. DISASSEMBLY ............................12 3.2.3. CHECK ..............................14 3.2.4. REASSEMBLY ............................15 3.2.5. INSTALLATION ............................

  • Page 30: Engine Accessories

    ENGINE MY 660 3.1. ENGINE ACCESSORIES 3.1.1. REMOVAL • Position the engine on the engine support (no. 8140839). NOTE Before removing the accessories, drain all fluids from the engine and set a suitable collector under it. • Undo the two screws and loosen the clips. •...
  • Page 31 ENGINE MY 660 • Remove the oil delivery hose, collect the O-ring. • Release the clamp and remove the oil tank breather hose. • Loosen and remove the two screws, remove the oil hose and collect the four washers. • Loosen and remove the two screws and remove the starter motor.
  • Page 32 ENGINE MY 660 • Release the clamp and remove the crankcase breather tank hose. • Loosen and remove the screw and remove the speed sensor. • Loosen the screw and disconnect the neutral sensor. • Loosen and remove the screw and remove the cable guide.
  • Page 33 ENGINE MY 660 • Remove the hose, collect the dowel and the snap ring. • Loosen and remove the screw (1), remove the cable ring (2). • Loosen and remove the two screws, remove the oil delivery hose and collect the four washers. •...

  • Page 34: Tightening Torque Settings

    ENGINE MY 660 3.1.2. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 ÷ 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 ÷ 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 ÷ 1.2 Bearing plate and oil filter screws 0.8 ÷...
  • Page 35 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 ÷ 1.5 Valve cover and timing cover screws 0.8 ÷ 1.2 Oil channel hose screws 1 1.6 ÷ 2.0 Spark plug 1.0 ÷ 1.5 Oil channel hose screws 2 1.7 ÷ 2.3 Oil channel hose side screw 2 0.8 ÷- 1.2 Intake manifold clamps screws...

  • Page 36: Water Pump

    ENGINE MY 660 3.2. WATER PUMP 3.2.1. REMOVAL WARNING Usually, it is not necessary to remove the coolant pump except in case the coolant level is extremely low or the coolant contains engine oil. NOTE Before removing the components, set a rag under the pump.
  • Page 37 ENGINE MY 660 • Remove the pump unit. • Release and remove the clamps. • Remove water jacket joint (6). • Slide out the water pump breather hose (7). • Unscrew and remove the screw. • Slide out the water pump outlet hose and collect the O- ring.
  • Page 38 ENGINE MY 660 • Remove the seal. 3 - 11...

  • Page 39: Disassembly

    ENGINE MY 660 3.2.2. DISASSEMBLY • Remove the circlip. • Remove the crankshaft gear. • Slide out pin and washer. • Remove the rotor shaft assembly. WARNING Carefully remove the component, do not damage it. 3 - 12...
  • Page 40 ENGINE MY 660 • Remove the support (1) and rubber dampener (2) from the rotor, using a screwdriver for flathead screws. WARNING Carefully remove the component, do not damage the rotor. • Remove the water pump seal using a small screwdriver.

  • Page 41: Check

    ENGINE MY 660 3.2.3. CHECK Component Ensure that water pump cover, water pump housing, rotor, rubber damper are not damaged or worn. Replace if necessary. Ensure that the water pump outlet hose, radiator outlet hose, water jacket outlet seat are not damaged or worn. Replace if necessary.

  • Page 42: Reassembly

    ENGINE MY 660 3.2.4. REASSEMBLY NOTE Lubricate the oil seal before installing, see (LUBRICANT TABLE). Apply an emulsified solution on the oil seal outer diameter to help installation, see (LUBRICANT TABLE). • Install a new oil seal (1) to the water pump housing. Install the oil seal using a suitably sized drift.
  • Page 43 ENGINE MY 660 • Should the reading not comply with allowed range, repeat rubber damper (6) and support (7) installation. • Install the crankshaft assembly. • Slide in washer and pin. • Install the rotor shaft gear with marking facing out (in view).

  • Page 44: Installation

    ENGINE MY 660 3.2.5. INSTALLATION WARNING When installing, only use new seals and clamps. NOTE Lubricate the oil seal before installing, see (LUBRICANT TABLE). Apply an emulsified solution on the oil seal outer diameter to help installation, see (LUBRICANT TABLE). •...
  • Page 45 ENGINE MY 660 • Install the pump unit. • Tighten the two screws. • Install the gasket (3). • Install water pump cover (4). • Install the washer (5). • Tighten the two screws (6). • Tighten the three screws (7). 3 - 18...
  • Page 46 ENGINE MY 660 • Fill the cooling system with specified quantity of recommended coolant. • Ensure there are no leaks, repair or change any faulty parts, if necessary. • Measure radiator cap opening pressure and change it if reading is lower than threshold value. 3 - 19...

  • Page 47: Tightening Torque Settings

    ENGINE MY 660 3.2.6. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 48 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 ÷ 1.5 Valve cover and timing cover screws 0.8 ÷ 1.2 Oil channel hose screws 1 1.6 ÷ 2.0 Spark plug 1.0 ÷ 1.5 Oil channel hose screws 2 1.7 ÷ 2.3 Oil channel hose side screw 2 0.8 ÷- 1.2 Intake manifold clamps screws...

  • Page 49: Cylinder Head

    ENGINE MY 660 3.3. CYLINDER HEAD 3.3.1. REMOVING THE CYLINDER HEAD • Using the suitable special tool (no. 8140850), loosen and remove the flywheel cover giving access to the crankshaft. • Using the suitable special tool (no. 8140850), loosen and remove the flywheel cover giving access to the timing reference.
  • Page 50 ENGINE MY 660 • Release and remove the two screws. • Remove the gearwheel inspection cover, collect the seal. • Ensure that reference mark “I” on camshaft gearwheel matches cylinder head fixed reference mark. • Loosen and remove the two screws and remove the timing chain tensioner.
  • Page 51 ENGINE MY 660 • Hold the flywheel nut with a wrench, loosen and remove the two screws on the camshaft gearwheel. • Remove the camshaft gearwheel. • Fix the timing chain with a tie. • Loosen and remove the four stud bolts in the order shown and collect the washers.
  • Page 52 ENGINE MY 660 • Release and remove the two screws. 3 - 25...
  • Page 53 ENGINE MY 660 • Remove the cylinder head, pay attention to the timing chain and to the decompression system since it is free to move in its housing. • Collect the seal and the two centring dowels. 3 - 26...

  • Page 54: Removing The Rocker Arms And Camshaft

    ENGINE MY 660 3.3.2. REMOVING THE ROCKER ARMS AND CAMSHAFT • Working on either side, loosen and remove the four screws. • Working on either side, remove the tappet cover, collect the O-ring. • Loosen and remove the two adjuster screws. •...
  • Page 55 ENGINE MY 660 • Using the suitable puller (no. 8140848), remove the decompression shaft. • Using the suitable puller (no. 8140848), remove the exhaust rocker arm shaft. • Remove the exhaust rocker arm. • Using the suitable puller, remove the intake rocker arm shaft.
  • Page 56 ENGINE MY 660 • Remove the intake rocker arm. • The camshaft hole is shaped to ease removal. • Carefully remove the camshaft, pay attention to the decompression chamber lever pin. 3 - 29...

  • Page 57: Removing The Valves And Valve Springs

    ENGINE MY 660 3.3.3. REMOVING THE VALVES AND VALVE SPRINGS NOTE The following procedure applies to all valves and their components. • Remove the rocker arms and camshafts, see (REMOVING ROCKER ARMS CAMSHAFTS). NOTE Before removing the cylinder head components (valves, valve springs, valve seats), ensure that the valves are closed and seal correctly.
  • Page 58 ENGINE MY 660 • Remove the valve stem oil seal (1) and valve spring seat (2). • Remove the valve. 3 - 31...

  • Page 59: Check

    ENGINE MY 660 3.3.4. CHECK CHECKING THE HEAD • Using a rounded-tip scraper, eliminate scale from combustion chamber. NOTE Do not use a tool with sharp edge or the spark plug thread and valve seats might be damaged or scratched. •...
  • Page 60 ENGINE MY 660 CHECKING THE CAMSHAFT GEARWHEEL • Check camshaft gearwheel for proper operation: change timing chain and camshaft gearwheel as a set if you notice damages or hard spots. CHECKING THE CAMSHAFT CAMSHAFT LOBES • Check for blueish stains, pitting, scratches and, if so, change camshaft and its gearwheel.
  • Page 61 ENGINE MY 660 CHECKING THE DECOMPRESSION SYSTEM • Check decompression system with the camshaft gearwheel and decompression pin installed to the camshaft. • Check that decompression lever pin (1) comes out further than the camshaft. • Check that decompression cam (2) is free to move with no jams.
  • Page 62 ENGINE MY 660 CHECKING VALVES AND VALVE GUIDES NOTE The following procedure applies to all valves and valve guides. • Using a micrometer, measure valve stem diameter (C). • Using an inner micrometer gauge, measure valve guide inner diameter (D). •...
  • Page 63 ENGINE MY 660 • Carry on checking valves and valve guides by eliminating scale from valve face and seat. • Ensure that the valve face does not show pitting or marks of wear; grind valve face if necessary. • Check that valve stem end does not have a "mushroom"...
  • Page 64 ENGINE MY 660 • Lap valve face and valve seat, as follows. NOTE Once head or valve and valve guide have been changed, valve seat and face should be lapped. • A - apply a (coarse grain) lapping compound to valve face (G).
  • Page 65 ENGINE MY 660 • Using a dynamometer, measure the compressed spring force with installed spring length of 35.00 mm (1.38 in). In case reading is not within indicated values, change valve spring. Compressed valve spring force (installed): 171 - 197 N at 35.00 mm (17.44 - 20.09 kg at 35.00 mm, 38.44 - 44.29 lb at 1.38 in).

  • Page 66: Installing The Valves And Valve Springs

    ENGINE MY 660 3.3.5. INSTALLING THE VALVES AND VALVE SPRINGS NOTE The following procedure applies to all valves and their components. • Deburr the valve stem ends. • Lubricate the valve stem and the valve stem oil seal with oil, see (LUBRICANT TABLE). •...
  • Page 67 ENGINE MY 660 • Install the valve spring retainer. • Compress the spring with suitable tool (no. 8140179) and install valve collets using adapter (no. 0276474). • Lightly tap with a mallet onto valve tip to secure valve collets to valve stem. WARNING Do not tap excessively hard on the valve or it might damage.

  • Page 68: Installing The Camshaft And Rocker Arms

    ENGINE MY 660 3.3.6. INSTALLING THE CAMSHAFT AND ROCKER ARMS NOTE Smear bearing with engine oil, see (LUBRICANT TABLE) and install it so that the oil seal faces (a) the camshaft. Lubricate the oil seal before installing, see (LUBRICANT TABLE). Apply an emulsified solution on the oil seal outer diameter to help installation, see (LUBRICANT TABLE).
  • Page 69 ENGINE MY 660 • Install the exhaust rocker arm. • Using puller (no. 8140848), install the intake rocker arm shaft. NOTE Ensure the rocker arm shaft is fully home in the head. • Fit intake rocker arm. • Install the bearing snap ring. 3 - 42...
  • Page 70 ENGINE MY 660 • Fit and tighten the two screws. 3 - 43...

  • Page 71: Installing The Head

    INSTALLING THE HEAD • Install the two centring dowels. • Install a new head gasket. NOTE Aprilia provides an additional gasket to be fitted under the head to compensate for any possible tolerance inaccuracy in the mating surfaces. • Install the head.
  • Page 72 ENGINE MY 660 • Tighten the two lower bolts to the specified torque. 3 - 45...
  • Page 73 ENGINE MY 660 WARNING When performing the following procedure, be careful not to turn the crankshaft otherwise damages or valve wrong setting might derive. • Ensure that slot (a) on decompression lever is in the position shown. • Set the flywheel rotor so as reference “I” (b) matches fixed reference (c) on magnet cover.
  • Page 74 ENGINE MY 660 • Snug the two screws of the camshaft gearwheel. • Install the chain tensioner as follows: • 1 – Remove the chain tensioner threaded plug (1), copper washer (2) and spring (3). • 2 – Release the chain tensioner single-direction cam (4) and push its rod (5) completely inside the chain tensioner housing.
  • Page 75 ENGINE MY 660 NOTE Ensure reference “I” (e) on gearwheel matches fixed reference (f) on the cylinder head. • If these references are not aligned, correct by repeating the same indicated operations; restart from installation of the camshaft gearwheel. • Tighten the two gearwheel screws.
  • Page 76 ENGINE MY 660 NOTE Smear the O-ring with grease, see (LUBRICANT TABLE). • Once renewed the O-ring, install the tappet cover in its seat. • Working on either side, tighten the four screws of both covers. • Fit the camshaft gearwheel cover. •...

  • Page 77: Tightening Torque Settings

    ENGINE MY 660 3.3.8. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 78 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 ÷ 1.5 Valve cover and timing cover screws 0.8 ÷ 1.2 Oil channel hose screws 1 1.6 ÷ 2.0 Spark plug 1.0 ÷ 1.5 Oil channel hose screws 2 1.7 ÷ 2.3 Oil channel hose side screw 2 0.8 ÷- 1.2 Intake manifold clamps screws...

  • Page 79: Cylinder And Piston

    ENGINE MY 660 3.4. CYLINDER AND PISTON 3.4.1. REMOVAL • Before removing the cylinder, first remove the cylinder head. • Remove the timing chain slider on the exhaust side. • Release and remove the two screws. • Remove the cooling system union, collect the seal. 3 - 52...
  • Page 80 ENGINE MY 660 • Loosen and remove the four stud bolts in the order shown and collect the washers. 3 - 53...
  • Page 81 ENGINE MY 660 • Release and remove the two screws. • Remove the cylinder, pay attention not to damage the chain and the piston. • Collect the centring dowels and the seal. 3 - 54...
  • Page 82 ENGINE MY 660 NOTE Before removing the gudgeon pin circlip, block off the casing opening with a clean cloth to prevent the circlip from falling inside the crankcases. • Mark the piston crown exhaust side to ensure correct reassembly. • Remove the gudgeon pin circlip.
  • Page 83 ENGINE MY 660 • Remove the top ring, the second ring, and the three scraper rings. 3 - 56...
  • Page 84 ENGINE MY 660 3 - 57...

  • Page 85: Check

    ENGINE MY 660 3.4.2. CHECK CYLINDER • All sealing surfaces should be clean and flat. • Ensure that all threads are in good condition. • Inspect the cylinder sliding surface and check for jams or scratches, check if the sealing surfaces are damaged.
  • Page 86 ENGINE MY 660 • Install the piston ring to the cylinder. • Make the piston ring flush with piston crown. • Measure piston ring end gap and change it if needed. NOTE It is not possible to measure the oil scraper ring end gap: if it shows excessive play, change the three piston rings.
  • Page 87 ENGINE MY 660 • Measure gudgeon pin inner diameter (b), change the gudgeon pin if out of allowed tolerance. Gudgeon pin inner diameter: 23.004 – 23.015 mm (0.9057 – 0.9061 in.) Service limit: 23.045 mm (0.9073 in.) • Calculate gudgeon pin to gudgeon pin hole clearance, change gudgeon pin and piston as a set if reading is out of allowed tolerance.

  • Page 88: Installation

    ENGINE MY 660 3.4.3. INSTALLATION NOTE When installing the piston rings, ensure the manufacturer reference or marking is facing up. • Install the top piston ring, the second ring, the oil scraper spring ring, the bottom oil scraper ring and the top oil scraper ring.
  • Page 89 ENGINE MY 660 • Fit the piston and install the gudgeon pin. NOTE Ensure that piston marking is facing the cylinder exhaust side. Before fitting the gudgeon pin, lubricate it with engine oil. NOTE Before fitting the gudgeon pin circlip, block off the casing opening with a clean cloth to prevent it from falling inside.
  • Page 90 ENGINE MY 660 • Fit the locating dowels. • Lubricate the piston, the piston rings and the cylinder with engine oil. • Check piston rings misalignment: measure ring end gap angles, as shown: a – top ring. b – top oil scraper ring c –...
  • Page 91 ENGINE MY 660 • Install the timing chain guide (exhaust side). NOTE Route the chain and its guide (exhaust side) through the timing chain notch. • Install four new washers with rounded surface up. WARNING Cylinder stud bolts are similar in pairs. The ones on timing side are longer.
  • Page 92 ENGINE MY 660 • Tighten the two screws. • Change the seal, tighten the two screws and secure the cooling system fitting. 3 - 65...

  • Page 93: Tightening Torque Settings

    ENGINE MY 660 3.4.4. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 94 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 ÷ 1.5 Valve cover and timing cover screws 0.8 ÷ 1.2 Oil channel hose screws 1 1.6 ÷ 2.0 Spark plug 1.0 ÷ 1.5 Oil channel hose screws 2 1.7 ÷ 2.3 Oil channel hose side screw 2 0.8 ÷- 1.2 Intake manifold clamps screws...

  • Page 95: Clutch

    ENGINE MY 660 3.5. CLUTCH 3.5.1. REMOVAL • Working in a cross pattern, loosen the seven screws by one fourth of a turn at a time until removing all seven screws. When have loosened screws completely, remove them. • Place a container of adequate capacity under the clutch.
  • Page 96 ENGINE MY 660 • Remove the pressure plate, collect disengagement shaft and pushrod. • Remove the thirteen clutch plates. • Remove the clutch damper spring and its housing. 3 - 69...
  • Page 97 ENGINE MY 660 • Straighten the lock washer, fit the universal clutch locking tool (tool no. 8600391), loosen and remove the clutch hub nut and collect the lock washer. • Remove the clutch hub and collect the thrust washer. • Remove the clutch housing.

  • Page 98: Check

    ENGINE MY 660 3.5.2. CHECK CLUTCH PLATES • Rest the friction plates and steel plates on a flat surface and check for cracks and deformation. Max. allowed flatness error 0.20 mm (0.0079 in.) NOTE The steel plates should not be scratched or stained. •...
  • Page 99 ENGINE MY 660 CHECKING THE CLUTCH HOUSING Check the clutch housing for damages and wear that might affect clutch operation. Possibly deburr the teeth or change the housing. CHECKING THE CLUTCH HUB Check the clutch hub for damages and wear that might affect clutch operation.
  • Page 100 ENGINE MY 660 CHECKING THE PRIMARY DRIVEN GEAR Check the primary driven gear for damages or wear and change the primary drive driving gear and the clutch housing as a set, if necessary. Check that it is not excessively noisy during operation; change primary drive driving gear and the clutch housing as a set, if necessary.

  • Page 101: Reassembly

    ENGINE MY 660 3.5.3. REASSEMBLY • Install the clutch housing. • Insert the washer. • Install the clutch hub. • Install a new locking washer. 3 - 74...
  • Page 102 ENGINE MY 660 • Using clutch locking tool (no. 8600391), tighten clutch hub nut to the specified torque • Bend the locking washer. • Turn the clutch housing with arrows up. • Lubricate the driving plates and the driven plates with engine oil.
  • Page 103 ENGINE MY 660 • Install the thirteen clutch plates, position them correctly. 3 - 76...
  • Page 104 ENGINE MY 660 3 - 77...
  • Page 105 ENGINE MY 660 3 - 78...
  • Page 106 ENGINE MY 660 • Position the clutch pusher plate with disengagement shaft. • Install the springs. • Tighten the screws with washers to the specified torque. 3 - 79...
  • Page 107 ENGINE MY 660 • Install the centring dowels. • Change the gasket and install the right casing. • Correctly fit the screws and tighten in a cross sequence. • Turn the disengagement shaft so as teeth face the vehicle rear end. 3 - 80...
  • Page 108 ENGINE MY 660 • Install the centring dowels. • Install a new seal. • Install the clutch casing. • Tighten the screws in a cross pattern. 3 - 81...
  • Page 109 ENGINE MY 660 • Fit the spring. • Set the release lever with “UP” upward. • Align the release lever reference mark to the clutch casing one. • Fit shim. • Fit the circlip. 3 - 82...
  • Page 110 ENGINE MY 660 • Install the spring to the release lever. 3 - 83...

  • Page 111: Tightening Torque Settings

    ENGINE MY 660 3.5.4. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 112 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 ÷ 1.5 Valve cover and timing cover screws 0.8 ÷ 1.2 Oil channel hose screws 1 1.6 ÷ 2.0 Spark plug 1.0 ÷ 1.5 Oil channel hose screws 2 1.7 ÷ 2.3 Oil channel hose side screw 2 0.8 ÷- 1.2 Intake manifold clamps screws...

  • Page 113: Oil Pump

    ENGINE MY 660 3.6. OIL PUMP 3.6.1. LUBRICATION SYSTEM DIAGRAM Key: A – To oil tank Oil delivery hose 2 Oil delivery tube 2 Oil filter Oil pump rotor 1 Oil pump rotor 2 Main shaft Oil delivery tube 3 3 - 86...
  • Page 114 ENGINE MY 660 Key: Camshaft Oil delivery tube 1 10. Oil filter 11. Main shaft 12. Driving shaft 13. Crankshaft 3 - 87...

  • Page 115: Removal

    ENGINE MY 660 3.6.2. REMOVAL • Before removing any components, place a container of adequate capacity under the engine. • Remove the clutch, see (REMOVING THE CLUTCH). • Loosen and remove the two screws and remove the oil baffle plate. •...
  • Page 116 ENGINE MY 660 • Unscrew and remove the screw. • Loosen and remove the three screws and remove the filter. • Remove the oil pump unit, collect the two O-rings. 3 - 89...

  • Page 117: Check

    ENGINE MY 660 3.6.3. CHECK Check oil pump driven gear for damages, wear or cracks. Change the part, if necessary. Check oil pump operation, change the oil pump as a set if faulty. 3 - 90...

  • Page 118: Installation

    ENGINE MY 660 3.6.4. INSTALLATION • Change the two O-rings and install the oil pump unit. • Fit the filter and secure it tightening the three screws. • Tighten the screw. • Change the O-ring. • Install the baffle plate and tighten the two screws. 3 - 91...
  • Page 119 ENGINE MY 660 • Tighten the two screws. • Install the oil pump gear (2) and change the safety snap ring (1). • Install the baffle plate and tighten the two screws. 3 - 92...

  • Page 120: Tightening Torque Settings

    ENGINE MY 660 3.6.5. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 121 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 ÷ 1.5 Valve cover and timing cover screws 0.8 ÷ 1.2 Oil channel hose screws 1 1.6 ÷ 2.0 Spark plug 1.0 ÷ 1.5 Oil channel hose screws 2 1.7 ÷ 2.3 Oil channel hose side screw 2 0.8 ÷- 1.2 Intake manifold clamps screws...

  • Page 122: Counter Shaft Driven And Driving Gear

    ENGINE MY 660 3.7. COUNTER SHAFT DRIVEN AND DRIVING GEAR 3.7.1. REMOVAL • Before removing any components, place a container of adequate capacity under the engine. • Remove the water pump unit, see (REMOVING THE WATER PUMP). • Remove the clutch housing, see (DISASSEMBLING THE CLUTCH).

  • Page 123: Connecting Rod Locking Tool

    ENGINE MY 660 • Remove the driven gear and collect the key. • Using the connecting rod locking tool (no. 8140387), lock the con rod while loosening and removing the balancer driven gear nut. • Collect the washer. • Remove the washer. •...
  • Page 124 ENGINE MY 660 • Remove the primary drive driving gear. • Remove the balancer driving gear and remove the key. • Remove the washer. 3 - 97...

  • Page 125: Check

    ENGINE MY 660 3.7.2. CHECK Check counter shaft driven gear and driving gear, water pump driving gear and primary drive gear for damage or wear. Change the parts, if necessary. 3 - 98...

  • Page 126: Installation

    ENGINE MY 660 3.7.3. INSTALLATION • Insert the washer. • Install counter shaft driving gear. • Install the key with rounded surface up. • Install the primary drive driving gear. 3 - 99...
  • Page 127 ENGINE MY 660 • Install the water pump driving gear. • Insert a new washer. • Install a new lock washer and nut. WARNING Ensure that the washer edge is inside keyway. Tighten primary drive gear nut to the specified torque and bend the edges.
  • Page 128 ENGINE MY 660 • Insert key and counter shaft driven gear. WARNING Align counter shaft driving gear reference mark to driven gear mark. • Tighten countershaft driven gear nut to the specified torque. • Bend the lock washers edges. • Install the right casing cover, see (HOW TO ASSEMBLE THE ENGINE CRANKCASES).

  • Page 129: Tightening Torque Settings

    ENGINE MY 660 3.7.4. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 130 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 - 1.5 Valve cover and timing cover screws 0.8 - 1.2 Oil channel hose screws 1 1.6 - 2.0 Spark plug 1.0 - 1.5 Oil channel hose screws 2 1.7 - 2.3 Oil channel hose side screw 2 0.8 - 1.2 Intake manifold clamps screws...

  • Page 131: Gear Shift Selector

    ENGINE MY 660 3.8. GEAR SHIFT SELECTOR 3.8.1. REMOVAL, INSPECTION, REFITTING REMOVAL • Remove the clutch, see (REMOVAL). • Remove the right casing, see (HOW TO TAKE THE ENGINE CRANKCASES APART). • Working on clutch side, release gear shift selector spring.
  • Page 132 ENGINE MY 660 • To disassemble the gear shift selector, proceed as follows. • Slide out the two washers (1) and (2). • Remove the snap ring (3). • Remove the washer (4). • Slide out the stop lever (5). •...

  • Page 133: Generator Side

    ENGINE MY 660 3.9. GENERATOR SIDE 3.9.1. REMOVAL • Release and remove the four screws. • Remove the cover together with torque limiter. • Collect the centring dowel. 3 - 106...
  • Page 134 ENGINE MY 660 • Loosen the nine screws in a cross pattern. • Mark the screws with different length. • Remove the flywheel cover with gasket, starter motor idle gear, four dowels and two O-rings. • Undo and remove the flywheel nut. •...
  • Page 135 ENGINE MY 660 • Position the flywheel locking tool. • Ensure flywheel is correctly locked. WARNING Do not touch the top projecting part of the flywheel with the locking tool. • Heat the flywheel with a suitable heater. • Using the suitable puller, remove the flywheel from the crankshaft.
  • Page 136 ENGINE MY 660 • Release and remove the two screws. • Remove the rear chain slider. • Remove the timing chain from crankshaft. 3 - 109...

  • Page 137: Check

    ENGINE MY 660 3.9.2. CHECK CHECKING THE BEARINGS AND OIL SEALS Carefully clean with a mild solvent the two crankcases, the ball bearings and all bearings seats. Clean the sealing surfaces and ensure they are not damaged. NOTE Set the two crankcases on a flat surface to avoid damages.

  • Page 138: Reassembly

    ENGINE MY 660 3.9.3. REASSEMBLY • Fit the rear chain slider. • Tighten the two screws. • Fit the timing chain to crankshaft. • Insert the washer. 3 - 111...
  • Page 139 ENGINE MY 660 • Install the roller cage. • Install the starter gear. • Fit the key into the crankshaft. • Install the flywheel, pay attention to the correct positioning of the key in its seat. 3 - 112...
  • Page 140 ENGINE MY 660 • Set the piston locking tools (no. 8600840) and flywheel tools (no. 8140838). WARNING Avoid touching the flywheel projecting parts with the locking tool. • Fit the washer into the crankshaft. • Tighten the nut to the specified torque. •...
  • Page 141 ENGINE MY 660 • Install a new seal. • Set the starter motor idle gear. • Insert the pin. • Fit the flywheel cover complete with stator. 3 - 114...
  • Page 142 ENGINE MY 660 • Correctly fit the nine screws and tighten in a cross sequence. • Fit the starter motor torque limiter. • Fit the centring dowel. • Install the torque limiter cover with a new gasket. 3 - 115...
  • Page 143 ENGINE MY 660 • Correctly fit the four screws and tighten in a cross sequence. 3 - 116...

  • Page 144: Tightening Torque Settings

    ENGINE MY 660 3.9.4. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 145 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 ÷ 1.5 Valve cover and timing cover screws 0.8 ÷ 1.2 Oil channel hose screws 1 1.6 ÷ 2.0 Spark plug 1.0 ÷ 1.5 Oil channel hose screws 2 1.7 ÷ 2.3 Oil channel hose side screw 2 0.8 ÷- 1.2 Intake manifold clamps screws...

  • Page 146: 3.10. Engine Crankcases

    ENGINE MY 660 3.10. ENGINE CRANKCASES 3.10.1. HOW TO TAKE THE ENGINE CRANKCASES APART • Before removing any components, place a container of adequate capacity under the engine. • Remove all accessories. • Loosen and remove the two screws and collect the washers.
  • Page 147 ENGINE MY 660 • Straighten the washer. • Undo and remove the nut and collect the washer. • Remove the front chain sprocket. • Remove the circlip. 3 - 120...
  • Page 148 ENGINE MY 660 • Working in a cross pattern, loosen the seven screws by one fourth of a turn at a time until removing all seven screws. • Release and remove all screws. • Loosen and remove the two screws and remove the support.
  • Page 149 ENGINE MY 660 • Working in a cross pattern, loosen the six screws by one fourth of a turn at a time until removing all six screws. • Release and remove all screws. • Use the connecting rod locking tool (no. 8600840) and the crankcase puller (no.
  • Page 150 ENGINE MY 660 • Remove the right casing. • Tie the gearbox shafts with rubber bands. • Remove the counter shaft. • Remove the gearbox shafts assembly. 3 - 123...
  • Page 151 ENGINE MY 660 NOTE Secure crankcase to engine supporting plate (no. 8140839). • Use the crankcase puller (no. 8140853) to remove the crankshaft. 3 - 124...

  • Page 152: Check

    ENGINE MY 660 3.10.2. CHECK CHECKING THE BEARINGS AND OIL SEALS Carefully clean with a mild solvent the two crankcases, the ball bearings and all bearings seats. Clean the sealing surfaces and ensure they are not damaged. NOTE Set the two casings on a flat surface to avoid damages.
  • Page 153 ENGINE MY 660 Check oil delivery tube for damage. Change the part, if necessary. Ensure that the oil delivery tube holes are not clogged and blow with compressed air to clean them, if necessary. 3 - 126...

  • Page 154: Assembling The Crankcases

    ENGINE MY 660 3.10.3. ASSEMBLING THE CRANKCASES NOTE Before reassembling, change and lubricate the oil seal and the bearing balls. • Install oil seals and bearings to the casings. • Using the special tool (no. 8140846), install the crankshaft to the left casing. •...
  • Page 155 ENGINE MY 660 • Install the right casing to the left casing, tap with a mallet, if necessary. NOTE Ensure that shafts turn correctly. • Install the six screws on left casing. • Tighten the six screws to the specified torque, in a cross pattern.
  • Page 156 ENGINE MY 660 • Secure the spring. • Insert the circlip. 3 - 129...

  • Page 157: Tightening Torque Settings

    ENGINE MY 660 3.10.4. TIGHTENING TORQUE SETTINGS DESCRIPTION ENGINE Oil seal plate screws 0.8 - 1.2 Sealant Threebond TB 1215 on thread Threaded pin 2.0 - 2.4 Loctite 620 on thread Clutch casing and Flywheel casing screws 0.8 - 1.2 Bearing plate and oil filter screws 0.8 - 1.2 Loctite 620 on thread Oil inlet hose screw...
  • Page 158 ENGINE MY 660 DESCRIPTION ENGINE Valve adjustment nuts 1.2 ÷ 1.5 Valve cover and timing cover screws 0.8 ÷ 1.2 Oil channel hose screws 1 1.6 ÷ 2.0 Spark plug 1.0 ÷ 1.5 Oil channel hose screws 2 1.7 ÷ 2.3 Oil channel hose side screw 2 0.8 ÷- 1.2 Intake manifold clamps screws...
  • Page 159 GEARBOX MY 660 GEARBOX 4 - 1...
  • Page 160 GEARBOX MY 660 SUMMARY 4.1. GEARBOX SHAFTS ............................3 4.1.1. DIAGRAM ..............................3 4.1.2. MAIN SHAFT DISASSEMBLY........................5 4.1.3. TRANSMISSION SHAFT DISASSEMBLY....................8 4.1.4. CHECK ..............................10 4.1.5. REFITTING THE PRIMARY SHAFT......................12 4.1.6. REFITTING THE SECONDARY SHAFT ....................15 4 - 2...

  • Page 161: Gearbox Shafts

    GEARBOX MY 660 4.1. GEARBOX SHAFTS 4.1.1. DIAGRAM Key: Counter shaft Primary shaft Secondary shaft Chain Wheel shaft 4 - 3...
  • Page 162 GEARBOX MY 660 Key: Gearbox fork “C” Gearbox fork “R” Gearbox fork “L” Gearbox drum 10. Primary shaft assembly 11. Spacer 12. Secondary shaft assembly 4 - 4...

  • Page 163: Main Shaft Disassembly

    GEARBOX MY 660 4.1.2. MAIN SHAFT DISASSEMBLY • Remove the circlip. • Remove the second-speed gear. • Remove the safety retaining washer. • Remove the fifth-speed gear and collect retainer, spacer and safety washer. 4 - 5...
  • Page 164 GEARBOX MY 660 • Remove the circlip. • Remove the third-speed gear. • Remove the circlip. • Remove the safety washer. 4 - 6...
  • Page 165 GEARBOX MY 660 • Remove the fourth-speed gear. 4 - 7...

  • Page 166: Transmission Shaft Disassembly

    GEARBOX MY 660 4.1.3. TRANSMISSION SHAFT DISASSEMBLY • Remove the circlip. • Remove the first-speed gearwheel and collect the washer. • Remove the fourth-speed gearwheel. • Remove the circlip. 4 - 8...
  • Page 167 GEARBOX MY 660 • Remove the third-speed gearwheel and collect the safety washer. • Remove the fifth-speed gearwheel. • Remove the circlip and then the second-speed gearwheel, collect safety washer and seal. 4 - 9...

  • Page 168: Check

    GEARBOX MY 660 4.1.4. CHECK CHECKING THE GEARBOX FORKS NOTE The following procedure applies to all gearbox forks. Check gear shift fork cam roller (1), gear shift fork tooth (2) for damage, deformation and wear. Change the gear shift fork, if needed. Check fork movement, change the forks if it is not smooth.
  • Page 169 GEARBOX MY 660 CHECKING THE GEARBOX With a dial gauge and a centring device, measure primary shaft runout, change the shaft if reading does not comply with recommended values. Maximum primary shaft runout: 0.08 mm (0.0031 in.) With a dial gauge and a centring device, measure secondary shaft runout, change the shaft if reading does not comply with recommended values.

  • Page 170: Refitting The Primary Shaft

    GEARBOX MY 660 4.1.5. REFITTING THE PRIMARY SHAFT • Install fourth speed gear. • Insert the safety washer. • Change the circlip. • Install third speed gear. 4 - 12...
  • Page 171 GEARBOX MY 660 • Change the circlip. • Fit the safety washer, the spacer, the retainer and install fifth speed gear • Fit the safety washer. • Install second speed gear. 4 - 13...
  • Page 172 GEARBOX MY 660 • Change the circlip. NOTE Ensure that the sharp edge (a) of circlips (2) is on the opposite side with respect to safety washers (1) and relevant gears. NOTE Install circlips so that both edges are at the centre of every groove.

  • Page 173: Refitting The Secondary Shaft

    GEARBOX MY 660 4.1.6. REFITTING THE SECONDARY SHAFT • Install second speed gear completed with seal and safety washer. • Change the circlip. • Install the fifth speed gear. • Install the third speed gear and safety washer. 4 - 15...
  • Page 174 GEARBOX MY 660 • Change the circlip. • Install the fourth speed gear. • Install the first speed gear and washer. • Change the circlip. 4 - 16...
  • Page 175 GEARBOX MY 660 NOTE Ensure that the sharp edge (a) of circlips (2) is on the opposite side with respect to safety washers (1) and relevant gears. NOTE Install circlips so that both edges are at the centre of every groove. 4 - 17...

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