APRILIA V990 Manual
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APRILIA V990 Manual

APRILIA V990 Manual

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V990 engine
6 engine -1
WORKSHOP manual
aprilia part# 8140586
Release 01/2001-10
U
01/2001-10
INTRODUCTION
GENERAL INFORMATION
TECHNICAL INFORMATION
DISASSEMBLING THE ENGINE
WORK ON THE INDIVIDUAL PARTS
REASSEMBLING THE ENGINE
ANALYTICAL INDEX
0
1
2
3
4
5
@
0
0
- 1
- 00

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Summary of Contents for APRILIA V990

  • Page 1 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...

  • Page 2: Table Of Contents

    INTRODUCTION V990 engine INTRODUCTION 4!",% /& #/.4%.43  50$!4% /& 2%,%!3%   ..0-3 0.1.1 INFORMATION ON THE UPDATING OF THE MANUAL ....0-3 0.1.2 UPDATED MANUAL GENERAL LIST ... 0-3  (/7 4/ #/.35,4 4(% -!.5!, ..0-4  &/2%7/2$ ..........0-5  2%&%2%.#% -!.5!,3 ......

  • Page 3: Information On The Updating Of The Manual

    INTRODUCTION V990 engine  50$!4% /& 2%,%!3%   pag.# Release pag.# Release 4 - 65 - 00 ......Date of the first edition (Release 00) and of the following 4 - 1 - 00 ......Releases: 4 - 66 - 00 ......
  • Page 4 INTRODUCTION V990 engine  (/7 4/ #/.35,4 4(% -!.5!, 1) Vehicle (or engine) model 6) Section page consecutive number 2) Section 7) Updated page consecutive number 3) Release consecutive number (“00” indicates the first 8) Chapter title (numbered consecutively) edition)

  • Page 5: Vehicle Workshop Manuals

    All rights as to electronic storage, reproduction and total or partial adaptation, with any means, are reserved for all Countries.

  • Page 6: Precautions And General Informations

    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 –...

  • Page 7: Advice For Consultation

    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.
  • Page 8 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 ≥...
  • Page 9 INTRODUCTION V990 engine NOTE - 00 Release 00/2001-06...
  • Page 10 INTRODUCTION V990 engine NOTE - 10 - 00 Release 00/2001-06...
  • Page 11 V990 engine GENERAL INFORMATION - 00 Release 00/2001-06...
  • Page 12 GENERAL INFORMATION V990 engine GENERAL INFORMATION 4!",% /& #/.4%.43  0/3)4)/. /& 4(% 3%2)!, .5-"%23 ..........1-3 1.1.1 ENGINE NUMBER ........1-3  ).3425#4)/.3 &/2 53% /& &5%, ,5"2)#!.43 #//,!.4 !.$ /4(%2 #/-0/.%.43 ....1-3 1.2.1 FUEL ............1-3 1.2.2 ENGINE OIL ..........1-3 1.2.3 COOLANT ..........

  • Page 13: Engine Number

    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.

  • Page 14: Coolant

    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.
  • Page 15 GENERAL INFORMATION V990 engine NOTE - 00 Release 00/2001-06...
  • Page 16 GENERAL INFORMATION V990 engine NOTE - 00 Release 00/2001-06...
  • Page 17 V990 engine TECHNICAL INFORMATION - 00 Release 00/2001-06...
  • Page 18  ,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 ......
  • Page 19 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...
  • Page 20 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;...
  • Page 21 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.).

  • Page 22: 30%#)!, 4//,3 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.
  • Page 23 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)

  • Page 24: Miscellaneous Tools

    TECHNICAL INFORMATION V990 engine 2.3.2 MISCELLANEOUS TOOLS - 00 Release 00/2001-06...
  • Page 25 8140395 [exhaust gas analyzer spare part: aprilia part# 8140196 (analyser)]. Particulate filter 8202222 (panel adhesive sheet) 8010396 [exhaust gas analyzer spare part: aprilia part# 8140196 (analyser). Tubular screen filter] 8010397 [exhaust gas analyzer spare part: aprilia part# 8140196 (analyser). Oxygen sensor] 8010398 [exhaust gas analyzer spare part: aprilia part# 8140196 (analyser).

  • Page 26: Tools Used For Other Aprilia

    TECHNICAL INFORMATION V990 engine 2.3.3 TOOLS USED FOR OTHER APRILIA 6%()#,%3 APRILIA part# (tool description and function) Pos. 0877650 (handle for pads) 0277265 (extractor for balance shaft, gearbox input and output shaft) – 8116050 (engine oil) – 8116053 (grease Bimol Grease 481) –...

  • Page 27: Product Properties

    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.

  • Page 28: Use Of Consumables

    (**) = 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.
  • Page 29 – 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.

  • Page 30: Joints With Click Clamps And Screw Clamps

    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).

  • Page 31: General Specifications Of The Driving Torques

    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).
  • Page 32 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.
  • Page 33 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...
  • Page 34 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)
  • Page 35 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.
  • Page 36 TECHNICAL INFORMATION V990 engine NOTE - 20 - 00 Release 00/2001-06...
  • Page 37 V990 engine DISASSEMBLING THE ENGINE - 00 Release 00/2001-06...
  • Page 38 DISASSEMBLING THE ENGINE V990 engine DISASSEMBLING THE ENGINE 4!",% /& #/.4%.43  4%#(.)#!, ).&/2-!4)/....3-3 3.1.1 TECHNICAL DATA ........ 3-3 3.1.2 MAINTENANCE INTERVALS ....3-3 3.1.3 TROUBLESHOOTING ......3-3 3.1.4 SEALANTS ..........3-3 3.1.5 LUBRICANTS ......... 3-3 3.1.6 SPECIAL TOOLS ........3-3 3.1.7 DRIVING TORQUE .........

  • Page 39: Driving Torque

    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).
  • Page 40 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.
  • Page 41 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.
  • Page 42 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.
  • Page 43 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...
  • Page 44 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.
  • Page 45 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.
  • Page 46 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).
  • Page 47 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.
  • Page 48 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.
  • Page 49 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).
  • Page 50 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).
  • Page 51 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;...
  • Page 52 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).
  • Page 53 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.
  • Page 54 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);...
  • Page 55 (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).
  • Page 56 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).
  • Page 57 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).
  • Page 58 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.
  • Page 59 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.
  • Page 60 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).
  • Page 61 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.
  • Page 62 DISASSEMBLING THE ENGINE V990 engine NOTE - 26 - 00 Release 00/2001-06...

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