Basic Information Identification Make: Aprilia Model: MY660 Motorcycle Year: 2003 Variant Identifier: MY660 Engine Introduction Market Position Manual Purpose: Designed to empower motorcycle owners and independent repair shops with the authoritative knowledge required for expert maintenance and repair of the 2003 Aprilia MY660 motorcycle engine and gearbox. Key Features Visual Aids: Contains numerous detailed photographs and clear diagrams, illustrating complex procedures and component identification, significantly enhancing understanding and execution of repairs. Value Proposition Diy Benefit: Enables users to perform their own repairs and maintenance, leading to significant cost savings compared to dealership labor rates. Step-by-step instructions cater to a wide range of skill levels. Manual Details Coverage Manual Type: Workshop Service/Repair Manual Coverage Areas: Engine, Gearbox, General Information, General Technical Information, Introduction Specifications Page Count: 175 Language: English Format: PDF Manual Coverage Systems Covered Engine Systems: Engine assembly, disassembly, lubrication, cooling, fuel delivery, ignition, exhaust, emissions control, engine diagnostics, component testing, overhaul procedures, critical torque specifications. Transmission Systems: Gearbox internal components, clutch operation, shifting mechanisms, gear lubrication, troubleshooting gearbox issues, disassembly and reassembly of transmission components. Procedures Included Maintenance Procedures: Regular scheduled maintenance, fluid level checks and changes, filter replacements, spark plug servicing, valve clearance adjustment, chain maintenance. Repair Procedures: Engine component repair and replacement (pistons, rings, valves, crankshaft, camshaft), gearbox repairs, seal and gasket replacement, troubleshooting common engine and gearbox faults. Technical Depth Depth Of Coverage: Comprehensive, covering detailed diagnostic procedures, component tolerances, wear limits, and complete engine and gearbox rebuilds, mirroring professional workshop practices. Manual Specifications File Properties File Format Details: Searchable PDF, allowing quick navigation and keyword-based information retrieval. High-resolution for clear image and diagram reproduction. Usability Print Quality: Printable on all pages, enabling users to print specific sections or the entire manual for in-garage use. Supports high-quality printing of diagrams and illustrations. Digital Compatibility: Compatible with both Windows and Mac operating systems for instant download and immediate access. Engine Specifications Primary Engine Details Engine Type: Likely a single-cylinder or parallel-twin configuration, typical for Aprilia's performance-oriented models of this era. Specifics would be detailed within the manual. Engine Details Bore X Stroke: Specific values to be found within the manual, crucial for engine rebuild calculations and piston selection. Compression Ratio: Detailed specifications for engine performance tuning and diagnostics will be included. Valve Train: Type (e.g., DOHC, SOHC), number of valves per cylinder, and adjustment procedures will be thoroughly covered. Fuel System Fuel Delivery System: Details on fuel injection systems (EFI) or carburetor specifications, including component testing and adjustment, will be present. Cooling System Cooling Type: Likely liquid-cooled; the manual will detail radiator, coolant, fan, and pump maintenance, as well as coolant specifications. Transmission Gearbox Configuration Gearbox Type: Likely a sequential manual transmission with a specific number of gears (e.g., 5 or 6 speed), detailed in the gearbox section. Gearbox Specifications Gear Ratios: Specific gear ratios for each speed will be provided, essential for performance analysis and troubleshooting shifting issues. Clutch Type: Information on the clutch mechanism (e.g., wet multi-plate) and servicing procedures, including adjustment and replacement, will be detailed. Fluid Requirements Transmission Fluid Type: Specific grades and specifications for transmission and clutch fluid, crucial for proper operation and longevity. Dimensions Engine Dimensions Engine Displacement Cc: The '660' in MY660 likely refers to an engine displacement of approximately 660 cubic centimeters. Specific bore and stroke figures will confirm this. Engine Weights Engine Dry Weight Kg: While not explicitly stated, the manual might contain information on the weight of the engine assembly for balance calculations or shipping purposes. Technology Features Engine Management Ignition System: Details on the electronic ignition system, including ignition timing, coil specifications, and sensor diagnostics (e.g., crankshaft position sensor). Fuel Management: Information on the fuel injection control unit (ECU) or carburetor settings, including idle control, throttle response, and sensor data interpretation. Maintenance Service Intervals Engine Oil Change: Specific mileage or time intervals for engine oil and filter changes will be detailed, typically around 3,000-5,000 miles or annually. Valve Clearance Check: Intervals for checking and adjusting valve clearances, critical for maintaining engine performance and preventing damage, likely around 10,000-15,000 miles. Transmission Fluid Change: Recommended intervals for transmission fluid inspection and replacement, crucial for gearbox longevity. Fluid Specifications Engine Oil Specification: Likely a high-quality synthetic or semi-synthetic motorcycle oil, with specific viscosity grades (e.g., 10W-40 or 15W-50) and API/JASO ratings to be found in the manual. Coolant Specification: Details on the type and mixture ratio of coolant (e.g., ethylene glycol-based) and its properties. Known Issues Common Wear Points: The manual will highlight common wear components such as valve guides, piston rings, clutch plates, and gearbox synchronizers, along with inspection criteria. Diagnostic Tips: Provides troubleshooting guides for typical problems like hard starting, poor idle, misfires, clutch slippage, and noisy gearbox operation. Vehicle History Brand Heritage Aprilia Heritage: Aprilia is an Italian manufacturer renowned for its sporty motorcycles, often featuring...