Aprilia Engines (50, 125, 150, 250, 300, 450, 550, 655, 660, 990) - Repair, Service and Maintenance Manual

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APRILIA ENGINES (50, 125, 150, 250, 300, 450, 550, 655, 660, 990) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for Aprilia Engines (50, 125, 150, 250, 300, 450, 550, 655, 660, 990).
 

ENGINES INCLUDED:

- APRILIA 50-1999 ENGINE
- APRILIA 50-2004 ENGINE
- APRILIA 125 ENGINE
- APRILIA 125-150 ENGINE
- APRILIA 125-150-180 ENGINE
- APRILIA 250-300 ENGINE
- APRILIA 450-550 ENGINE
- APRILIA 655-95 ENGINE
- APRILIA 655-97 ENGINE
- APRILIA 660 ENGINE
- APRILIA V990 ENGINE
- APRILIA V990 RR ENGINE


SAMPLE INDEX MANUAL:

- Recurrent symbols  6
- General precautions and safety rules  6
- Parts - list  9
- Engine serial number - position  9
- Technical data type 120 Leonardo and 120 Scarabeo 10
- Technical data type 154 Leonardo and 154 Scarabeo 12
- Technical data type 177 Scarabeo 14
- Engine servicing schedule 16
- Servicing and repair requirements 16
- General notes on servicing and repair procedures 18
- Fault finding 20
- Service tools, equipment, sealing and lubricating agents 27
- Standard tools 30
- Measuring instruments 30
- Fasteners 30
- Sealing and lubricating agents 31
- Torque wrench settings34
- Oil circuit 39
- Repairs without removing engine 40
- Removing engine from frame 41
- Positioning engine on stand 42
- Starter motor — remove 43
- Variator cover— remove 43
- Carburetor hose and valve cover — remove 44
- Locking crankshaft at top dead center 45
- Timing chain — check 47
- Chain tensioner and timing gear — remove 47
- Cylinder head — remove 48
- Chain guide and chain tension guide — remove 49
- Cylinder — remove 49
- Piston — remove 50
- Oil filter and oil pressure switch — remove 51
- Ignition and electric starter gearing — remove 51
- Oil pump — remove 53
- Water pump — remove53
- Chain tension guide and timing chain — remove 55
- Oil strainer — remove 55
- Variator — remove 56
- Oil pressure valve 58
- Transmission — remove 58
- Half crankcase — separate 61
- Crankshaft — remove 62
- Crankcase63
- Half crankcase, flywheel side (MS) — flywheel side servicing 65
- Half crankcase, clutch side — removal and refitting of plain bearings,
- ball bearings, oil seal, etc 69
- Transmission cover — servicing76
- Crankshaft 80
- Transmission 82
- Variator, primary drive side — check 83
- Secondary drive 87
- Timing gear 91
- Chain guide and chain tension guide 92
- Oil pump and water pump gearing 92
- Oil pressure retaining valve 94
- Cylinder95
- Piston and piston pin 95
- Piston rings 97
- Cylinder head 99
- Valves  102
- Valve seats  103
- Rocker arms  105
- Thermostat — check (Leonardo 120 only)  107
- Valve cover  108
- Ignition  109
- Ignition cover  112
- Spark plug 113
- Electric starter gearing  114
- Idle gear  115
- Starter motor 115
- Half crankcase, flywheel side  116
- Half crankcase, clutch side  117
- Oil strainer and magnetic drain plug — refit  123
- Piston — refit  124
- Cylinder — refit  125
- Chain guide and chain tension guide — refit  127
- Cylinder head — refit  127
- Chain tensioner — refit 128
- Valve clearance — adjust  129
- Oil filter — refit  130
- Flywheel side components — refit  130
- Water pump, idle gear and ignition cover — refit  131
- Carburetor hose — refit  134
- Starter motor — install  134
- Variator cover — refit  134
- Refitting engine onto frame  135
- Filling  135
- Engine test  137