Description

Aprilia 655 1995 Repair Manual

I’ve been wrenching for 28 years, and the first thing I’ll tell you about the 1995 Aprilia 655 with the Rotax engine is this: you don’t guess torque specs on that motor. A friend of mine at a shop in Austin ignored the factory numbers on a valve cover job and ended up with a warped head. This Repair Manual is the one Bombardier-Rotax and Aprilia themselves put out – 149 pages of actual procedures, not some aftermarket translation that leaves out half the steps. If you’re holding a wrench on a 655, you need this on the bench.

Engine Removal and Trestle Setup – Page 30

The manual calls out engine removal starting on page 30. It specifies the exact sequence: disconnect the electric starter (page 32), pull the valve cover (page 32), set the crankshaft to TDC (page 33). I’ve seen guys skip the trestle step and try to work on the motor lying on its side – you’ll bend a cooling line or crack the crankcase every time. The factory says to mount it on a trestle before disassembly. Do that. And use the special tools listed on page 19 – the clutch holding tool, the chain tensioner pin.

Tightening Torques: Page 22 – Non-Negotiable

Page 22 is the one you’ll wear out first. That’s the tightening torque table – head bolts, crankcase screws, clutch hub nut, everything. No aftermarket book I’ve seen gets these right. The manual includes the securing and lubricating agents for each fastener (Loctite types, oil grades). If you’re doing a top-end rebuild, you need the exact Nm values for the cylinder head and cylinder base. Specs are in Nm – convert to ft-lb if you must, but use a torque wrench that reads in both. I’ve had to re-torque three heads last month from guys using generic values. Don’t be that guy.

Cooling Circuit and Lubrication System Layout

On page 11 the manual shows the full cooling circuit diagram – water pump routing, thermostat location, bleed points. The Rotax 655 has a wet sump lubrication system with two oil pumps (page 55). Page 10 covers the oil pressure regulating valve and the retaining valve. Overheating on these engines is often a stuck thermostat or a clogged water passage near the cylinder. The factory schematic makes it obvious where to check first. Cooling system failure will kill this motor fast – the manual gives you the bleed procedure step by step.

Crankshaft Bearing Radial Clearance – Page 49

Page 49 walks you through measuring crankshaft bearing radial clearance. You’ll need a micrometer and a bore gauge – the manual tells you the exact limits. If you’re rebuilding the bottom end, skip this step and you’ll be splitting the case again in 500 miles. The Rotax uses split-sleeve bearings on the 655 version (crankshaft bushings, as the cover states). Clearance specs are given in mm – don’t approximate. I’ve got a box of ruined bearings from guys who thought ‘close enough’ was a spec.

Clutch and Primary Drive Assembly – Page 68

The clutch section starts at page 38 with clutch cover removal, then page 39 for clutch and primary drive disassembly. Page 68 gets into the details – clutch basket, friction plates, steel plates, and the primary drive gear. The manual calls out the order of the plates and the spring free length. Aftermarket guides often mix up the clutch pack order on the 655, causing slippage. Factory procedure: measure each friction plate thickness (wear limit listed), inspect the clutch hub for notching, and replace the oil seal on the main shaft (page 38) if you’re in there.

FAQ

Does this manual cover the electrical system and wiring?

No. This is a Rotax engine repair manual – it covers the engine, cooling, lubrication, and clutch. Wiring diagrams and body electrical are in the Aprilia motorcycle service manual. Check the Aprilia RSV mille 1999 Training Manual if you need electrical for that generation.

What language is the manual in?

German and English side-by-side. The preface and TOC are bilingual.

If you’re rebuilding a Manual Transmission Manual Transmission on any bike, the principles of gearbox disassembly (page 44) and shift mechanism (page 65) apply here – but the 655’s ratios and end float specs are specific. Another resource to cross-reference is the Manual Transmission repair section in the Rotax engine manual itself. For other Aprilia projects, look at the Aprilia RS 125 Workshop Manual – Factory Specs for 2-Stroke or the Aprilia RST mille 2002 Workshop Manual. Don’t mix manuals – each model has its own torque chart.

Access the Factory Manual.