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V990 engine INTRODUCTION GENERAL INFORMATION TECHNICAL INFORMATION DISASSEMBLING THE ENGINE WORK ON THE INDIVIDUAL PARTS REASSEMBLING THE ENGINE ANALYTICAL INDEX 6 engine -1 01/2001-10 WORKSHOP manual aprilia part# 8140586 - 00 Release 01/2001-10...
Keep away from the red-hot parts of the engine, in or- a/o noise otherwise they must be replaced. der to avoid burns. – Use only original aprilia SPARE PARTS. WARNING – Use the recommended lubricants. Do not hold any mechanical piece or other parts of –...
INTRODUCTION V990 engine (/7 4/ 53% 9/52 7/2+3(/0 -!.5!, 0.6.1 ADVICE FOR CONSULTATION – This manual is divided into section and chapters, each one of which corresponds to a category of main com- ponents. To consult them, see the sections’ index, see page 0-1.
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INTRODUCTION V990 engine !""2%6)!4)/.3 39-"/,3 ).)4)!,3 = number PICK-UP = pick-up < = is less than = bottom dead centre > = is greater than = top dead centre ≤ = is equal to or less than = Pneumatic Power Clutch ≥...
GENERAL INFORMATION V990 engine 0/3)4)/. /& 4(% 3%2)!, .5-"%23 These numbers are necessary for the registration of the vehicle. Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. 1.1.1 ENGINE NUMBER The engine number is stamped on the rear part of the en- gine, near the pinion.
CAUTION and consult a doctor. Failure to use APRILIA Genuine Spare Parts may re- If it is swallowed, induce vomit, rinse mouth and sult in incorrect performance and damages.
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GENERAL INFORMATION V990 engine NOTE - 00 Release 00/2001-06...
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GENERAL INFORMATION V990 engine NOTE - 00 Release 00/2001-06...
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V990 engine TECHNICAL INFORMATION - 00 Release 00/2001-06...
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,5"2)#!.4 #(!24 ........ 2-5 30%#)!, 4//,3 m ........ 2-6 2.3.1 ENGINE TOOLS ........2-6 2.3.2 MISCELLANEOUS TOOLS ....2-8 2.3.3 TOOLS USED FOR OTHER aprilia VEHICLES ..........2-10 #/.35-!",%3 ........2-11 2.4.1 PRODUCT PROPERTIES ....2-11 2.4.2 USE OF CONSUMABLES ....2-12 &!34%.).' %,%-%.43 ......
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TECHNICAL INFORMATION V990 engine 4%#(.)#!, 30%#)&)#!4)/.3 ENGINE Model V990 Type 60° longitudinal V-type, two-cylinder, 4-stroke, with 4 valves per cylinder, DOHC. Number of cylinders Total displacement W w (’98 – ’99 – 2000 models) ñ 997.6 cm# Total displacement W w (models starting from 2001) ü...
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TECHNICAL INFORMATION V990 engine ã Follow ENGINE Spark advance At start: 5° before TDC, additional advance depending on specific consumption levels Starter motor gear ratio i= 49/9 * 30/11 * 64/30 = 31.677 Clutch multidisc in oil bath, with hydraulic control on the left side of the handlebar and PPC device - # 9 friction discs;...
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TECHNICAL INFORMATION V990 engine ã Follow FUEL SUPPLY SYSTEM Type electronic injection Choke W w ñ å Ø 51 mm Choke ü Ø 47 mm FUEL SUPPLY Type indirect injection (MULTIPOINT) Fuel pr emium grad e unleaded petrol , m in. O.N . 95 (N.O.R.M.) and 85 (N.O.M.M.).
TECHNICAL INFORMATION V990 engine 30%#)!, 4//,3 m 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 dam- age as a result of inappropriate tools and/or improvised methods.
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TECHNICAL INFORMATION V990 engine APRILIA part# (tool description and function) Pos. 8140175 (complete tool kit for engine including) 0277680 (gearshift secondary shaft oil seal assembly pad) 0277660 (secondary countershaft oil seal assembly pad) 0277670 (coolant pump shaft housing oil seal assembly pad)
2.4.1 PRODUCT PROPERTIES APRILIA part# (product) Use and properties ® aprilia part# 0897651 [LOCTITE Adhesive in paste for screws and nuts up to M36 and for 243 blue (10 cm³)] couplings with medium hold. It can be used on parts which have not been completely degreased.
(**) = see 2.4.1 (PRODUCT PROPERTIES). xxxxxxx N.A. = not available APRILIA part# (product) Description of use aprilia part# 8116050 (engine oil) (*) – On timing intermediate gear roller bearings. – On lower countershaft thrust washer. – Clutch disengaging shaft.
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– On driving shaft and countershaft housings. – On connecting rod/piston pin slots. – On camshaft cams. – On starter motor fastening housing. aprilia part# 0297386 [SILASTIC 732 RTV (100 – On cable bracket on flywheel cover. g)] (**) – On camshaft sensor cable.
NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (click clamp installation pliers). CAUTION Upon installation, replace the click clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
TECHNICAL INFORMATION V990 engine 2.5.2 GENERAL SPECIFICATIONS OF THE DRIVING TORQUES The following table indicates the standard driving torques for screws and bolts with metric ISO thread. Driving torque Screw or Spanner bolt thread 13.0 For specific joints or couplings of the vehicle, see 2.5.3 (DRIVING TORQUE).
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TECHNICAL INFORMATION V990 engine 2.5.3 DRIVING TORQUE CAUTION NOTE The fastening elements featured in the table must be ® L243 = fasten with LOCTITE torqued to specification using a torque spanner and ® ® L572 = fasten with LOCTITE LOCTITE applied, where indicated.
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TECHNICAL INFORMATION V990 engine ã Follow Engine casing Screw T.C.E.I. Bearing flange [flywheel side (MS)] – M8 x 20 Screw T.C.E.I. Bearing flange [flywheel side (MS)] L243 M6 x 20 Oil pump Description Q.ty Screw/nut Note L648 on both Without head screw...
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TECHNICAL INFORMATION V990 engine ã Follow Head, cylinders varnished head version 58 Nm (5.8 kgm) varnished Grease head version the nut Head/stud bolt Nut M10 50 – 55 Nm support (5.0 – 5.5 kgm) surface varnished head version (with nut on outer side) 58 Nm (5.8 Kgm)
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TECHNICAL INFORMATION V990 engine ã Follow Ignition system, starter motor Description Q.ty Screw/nut Note Taptite screw W w Driving shaft position sensor/flywheel cover – M6 x 16 Taptite screw å ü Revolution number sensor/flywheel cover L243 M6 x 12 Screw T.C.E.I.
DISASSEMBLING THE ENGINE V990 engine 4%#(.)#!, ).&/2-!4)/. 3.1.1 TECHNICAL DATA See 2.1 (TECHNICAL SPECIFICATIONS). 3.1.2 MAINTENANCE INTERVALS See 0.4.1 (VEHICLE WORKSHOP MANUALS). 3.1.3 TROUBLESHOOTING See 0.4.1 (VEHICLE WORKSHOP MANUALS). 3.1.4 SEALANTS See 2.4 (CONSUMABLES). 3.1.5 LUBRICANTS See 2.2 (LUBRICANT CHART).
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DISASSEMBLING THE ENGINE V990 engine 3.1.8 PRECONDITIONS TO BE MET WHEN PERFORMING MAINTENANCE AND REPAIR WORK WARNING During the assembly phase, bear in mind the engines weight (approx. 65 – 67 kg) and centre of gravity: sup- port accordingly. Take care around any potentially hazardous points where you might be squashed or cut.
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DISASSEMBLING THE ENGINE V990 engine 3.1.10 SPECIAL MARKS ON THE ENGINE For disassembly, reassembly and replacement purposes, some parts of the engine are marked with coloured points, letters or reference marks. The table indicates the part (seat and element), the type of mark, the mark function and the reference to the man- ual chapter or paragraph.
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DISASSEMBLING THE ENGINE V990 engine $)3!33%-",).' 4(% %.').% 3.2.1 ENGINE DISASSEMBLY SEQUENCE CAUTION NOTE This diagram shows the operations to be per- Any components removed must be set aside in formed and the sequence to be followed when disassem- groups according to the respective assembly posi- bling the engine parts.
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DISASSEMBLING THE ENGINE V990 engine ã Follow 32) Front cylinder head 33) Front cylinder head with cylinder 1) Engine 34) Rear cylinder top side countershaft 2) Starter 35) Rear cylinder timing chain 3) Flywheel cover 36) Clutch discs 4) Oil filter cover...
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DISASSEMBLING THE ENGINE V990 engine 2%-/6).' 4(% 34!24%2 -/4/2 NOTE The following operations can be performed with- out removing the engine from the frame. Move the protection element aside, unscrew and re- move the nut, recover the washer and disconnect the cable of the starter motor.
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NOTE Have the appropriate special tool m to hand: – aprilia part# 0240880 (threaded bolt to lock the drive shaft at the TDC) (12). Screw the special tool (12) into the slot previously oc- cupied by the M8 T.C.E.I.
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DISASSEMBLING THE ENGINE V990 engine ã Follow WARNING Be careful to avoid possible injury caused by allow- ing hands to get trapped between the cylinder and the stud bolts (24). Remove the cylinder (25) together with the complete head (26).
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NOTE Have the appropriate special tool m to hand: – aprilia part# 0240880 (threaded bolt to lock the drive shaft at the TDC) (15). IN IN Screw the special tool (15) into the slot previously oc- cupied by the M8 T.C.E.I.
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DISASSEMBLING THE ENGINE V990 engine ã Follow Unscrew and remove the closing screw (16) complete with seal (17) and remove the complete chain tightener (18). Insert an appropriate drift (Ø 7.5 mm) (19) in the upper countershaft hole (20). CAUTION When loosening the nut M14x1 (21), counter the force with the drift (19) so as not to strain the driving chain.
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DISASSEMBLING THE ENGINE V990 engine ã Follow Unscrew and remove the two M6 T.C.E.I. screws (33) and four M10 nuts (34). WARNING Be careful to avoid possible injury caused by allow- ing hands to get trapped between the cylinder and the stud bolts (35).
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M6 T.C.E.I. screws (1). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277252 (flywheel magneto cover remov- al tool) (2). Screw the special tool (2) onto the flywheel cover (3). Lift the flywheel cover (3).
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V990 engine ã Follow NOTE Have the appropriate special tool m to hand: – aprilia part# 0277730 (flywheel removal hexagonal bolt) (7). Screw the special tool (7) into the thread of the flywheel (8). CAUTION Do not heat the hub of the magneto flywheel (8) over a flame;...
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DISASSEMBLING THE ENGINE V990 engine $)3!33%-",).' &2/.4 #9,).$%2 4)-).' $2)6% !33%-",9 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed with- out removing the engine from the frame. Unscrew and remove the M10 T.C.E.I. screw (1).
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DISASSEMBLING THE ENGINE V990 engine 2%-/6).' 4(% -/4/2 /), &),4%2 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed with- out removing the engine from the frame. CAUTION In order to avoid any contact with used oil, wear pro- tective gloves.
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DISASSEMBLING THE ENGINE V990 engine 2%-/6).' 4(% #,54#( #/6%2 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed with- out removing the engine from the frame. Drain the engine oil, see 0.4.1 (VEHICLE WORKSHOP MANUALS);...
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(4). Remove the complete clutch disengaging shaft (5). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140185 (clutch disc extraction hook le- ver) (9). NOTE The lower clutch discs can only be removed in- dividually with the aid of the appropriate hook levers (9).
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DISASSEMBLING THE ENGINE V990 engine $)3!33%-",).' 4(% #/5.4%23(!&4 -%#(!.)3- !.$ 02)-!29 42!.3-)33)/. Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The driving shaft must be retained at TDC, see 3.4 (DISASSEMBLING FRONT CYLINDER, HEAD AND PISTON). Unscrew and remove the M22x1.5 T.E. nut (1), remove the spring washer (2) and countershaft counterweight (3).
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DISASSEMBLING THE ENGINE V990 engine $)3!33%-",).' 2%!2 #9,).$%2 4)-).' $2)6% !33%-",9 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the drive gear (1) from the driving shaft. Unscrew and remove the three M8 T.E. screws (2) and detach the lock washers (3).
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DISASSEMBLING THE ENGINE V990 engine 2%-/6).' 4(% /), 05-0 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The oil pump gears, both driving (1) and driven (2), must always be replaced once they have been disas- sembled. NOTE The oil pump drive gear (1) is attached to the support plate of the complete clutch housing.
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DISASSEMBLING THE ENGINE V990 engine $)3!33%-",).' 4(% '%!2 3%,%#4)/. -%#(!.)3- Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Unscrew the threaded pin M8 (1) retaining the driving shaft at TDC. NOTE Turn the driving shafts by hand to enable the gear to engage.
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DISASSEMBLING THE ENGINE V990 engine 30,)44).' 4(% %.').% #!3).' /0%. Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Take the seeger ring (1) and thrust washer (2) off the secondary shaft. Unscrew and remove the twenty M6 T.C.E.I. screws (3).
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DISASSEMBLING THE ENGINE V990 engine $)3!33%-",).' 4(% '%!23()&4 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the two spindles (1). Turn both gearshift forks (2) of the secondary shaft (3) outwards, moving them away from the guides of the se- lector cylinder (4), and remove them.