Aprilia Falco Sprag Clutch Replacement (V990 Gen 1-Falco, Tuono, Mille)
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- Опубліковано 8 лют 2020
- This is a how-to for replacing a Aprilia Falco Sprag Clutch (applies to V990 Gen 1-Falco, Tuono, Mille). It’s intended to be a help for those who are concerned about doing the service themselves. Aprilia’s dealer network is fairly sparse (here in the States), so much of the work must be done by the owners. Please feel free to comment helpful hints or where I might have something incorrect.
- Фільми й анімація
Just found my sprag clutch has gone on mine(Following a lay up oddly!) . This video is very detailed and clear, cheers!
Thank you!
Great vid mate. Doing mine now👍
Thankyou for a fantastic tutorial. I've got to do my 2004 rsv tuono and this has given me the confidence. Bless you.
Awesome! The worst part is breaking the flywheel nut. I cannot stress enough the importance of a lot of heat. I bought a cheap heat gun and left it on for something like 20-30 minutes. The bolt was super hot and it then came loose.
amazing video, well done. im gonna do that to my tuono soon
Thank u very much for taking the Time to show us how to fix sprag appreciate it very much as for the two thumbs down haters gotta hate mate
You're welcome! It seemed very daunting when I was researching how to change it. I couldn't find any other videos, so I decided to help others out and make a video myself. I'm obviously not a professional UA-camr. Ha! But hopefully, I can shed some light on the process so someone in the same predicament can fix their own, given the small Aprilia dealer network. The early Aprilias are such good bikes.
Very helpful video, thank you! I will be doing mine soon, watching this with a strong cup of tea really helps me prepare... 🏍
Thank you! Honestly wasn't very difficult. Having time to work on it is helpful! I couldn't find anything "out there" in video form that would allow me to watch over someone's shoulder. Hopefully - this helps folks enjoy their Get 1 Aprilias more. They're fantastic motorcycles.
Awesome job fella 👍..Bike looks great. I guess I will be doing this sometime.. 🍺
christopher gray Thank you! Certainly not professional grade video; however, I hope it’s beneficial to someone needing to complete the repair.
@@motorcyclemicah6309 Your more than welcome mate. Don't under sell your efforts, it's nigh on perfect. I came from the Aprilia forums, I am the 848 fork swap fella. Cheers!
christopher gray Thank you again! I appreciate you comments. When the weather warms up, I intend to video how to change tires. Shops here charge a lot, and they don’t include balancing. I’m hoping that video will be helpful for others as well. Thanks again!
Tom Bryson That’s a great idea! I’ll film once mine need to be replaced.
By the way, as you don’t have the crank locking tool, consider locking the rear wheel by using a piece of wood through the wheel spokes in order to achieve proper torque on the crank bolt.
Me too Mille
Great Job with the video, I should make one too I have had the same problem on a beat up broken 99 rsv1000 it ended up in my hands and I turned into a cafe racer since it was destroyed, sprang cluch was a repeated problem, I went with a few chinese replacements, and eventually I took a shot since parts looked identical and I got an OEM sprang assembly from ebay but from a 2008 Tuono. It worked great! and I love this bike its built like a tank with awesome handling abilities and one of the greatest sounds .. except for the sprag assembly problem. I think your sprang cluch also looks the same as mine, I hope I never have to do another replacement however I'd like to know which model replacement you used from the ktm. I think I had considered it at one time but never tried it. Oh for whomever made it this far into my rumble, note if you have the bike lifted while working on it, and after you get done and it doesn't start, before you waste time start with the simple stuff. #1 side stand to be up. #2 (happened to me), 1st gear was in and it took me 2 hours to figure it out after I did fuel and electrical testing :-). All good, awesome bikes.
Thanks! Definitely make a video or two!
Great video and so useful to people who take care on his bikes.
Please could you inform us about the nºparts that you have replace ? i'm talking about the flywheel and the housing, that was impossible to me found them on internet, which parts of ktm match with the aprilia ones.
Sorry about my english....
www.apriliaforum.com/forums/showthread.php?155882-How-to-replace-your-sprag-clutch
The above post includes part numbers. You may have order from a US dealer.
Apart from sprag clutch wot else do I need to budget for i really love the sound of these
You'll want the flywheel. Check these posts:
www.apriliaforum.com/forums/showthread.php?319011-Sprag-Clutch&highlight=sprag+replace
www.apriliaforum.com/forums/showthread.php?155882-How-to-replace-your-sprag-clutch
Excellent work. I need to replace the stator but it is good to know how to do the spray clutch as well.
how come this part fails? i have rsv 1000r from 2007 with 6000 miles . I have had a bad battery for long time and i will change it tomorrow. Do I need to worry?
I wouldn't worry about it until the part actually fails. You'll hear the starter spinning without engaging the motor, which is when you'll know one of the starter clutch ("sprag") components has failed. Keep a strong battery, and keep the battery on a battery charger to keep it maintained. A strong battery, per my understanding, is the best way to keep a starter sprag in good health. 6k miles is not a lot of miles though. Mine went 22k miles or so before needing to be replaced.
Is the Orientation of the Bolt/PIn of the intermediate starter gear important`? Pulled it out and not sure if i put it back in the same way.
Yes, it’s important. The gear will not sit flush (if I remember correctly). On the video, you can see the orientation.
@@motorcyclemicah6309 I'm meaning the Pin/Axle itself where you put the gear onto, not the gear itself (there i put the "flange" backwards facing).
@@andrean_7725 Honestly, I’m not sure as I didn’t pull out the shaft upon which the gear rides. If there are no mating slots on the internal-to-the-engine side, then I would not think it matters. The gear simply spins on that shaft. The cover should have no issue going on.
Hello there, does the cam/crank sensor goes in there, in the case, if not could you please indicate where.
Many thanks
I don’t recall removing the crank sensor for this project.
where can i get the screw to unscrew for the pole wheel?
I got mine from AF1 Racing. www.af1racing.com/store/Scripts/prodList.asp?idCategory=49&description=Falco+Maintenance%2C+Tools%2C+and+Chemicals
hi m8 fantastic vid what ktm is the sprag clutch of that you are fitting in your apriia and woul it fit a tuono 2006 cheers m8
David Hopkins I don’t think it will fit a 2006 Tuono, unless it uses the Gen 1 engine. By that time, Aprilia was using the Gen 2 (I think).
David Hopkins I don’t think it will fit a 2006 Tuono, unless it uses the Gen 1 engine. By that time, Aprilia was using the Gen 2 (I think).
Great video! I am new owner of tuono 1 gen and i have some questions for you. How do you spot a bad sprag clutch please? When im starting the bike when its cold i use full Gas lever and its starts fine. When i start the bike when its warm and when im not using throttle while starting it then it will start make noise like clanking. I had bad battery Last week and when i tried to start it and it was making the same sound si i stopped trying and buyed a new battery. My question is if that sound is normal. Thank you and sorry for my english.
TheLowabot no worries on the English. A bad sprag causes the starter to spin, but the engine does not. So it sounds pretty bad as the sprag clutch “teeth” are not biting on to the flywheel. At the end of my video, you should see and hear what a normal start sounds like. Note that the noise coming from the bike when I turn the key to the “on” position is the fuel pump, which is noisy if I leave the bike for a few weeks. That was it’s first start in 5 months.
@@motorcyclemicah6309 Thank you for the answer. Mine makes sound like this ua-cam.com/video/xr2Dv2r_sA0/v-deo.html.
@@TheLowabot That sounds like a sprag letting go. The repair isn't too bad at all, though it's a little time consuming. Install the new battery, and then test it out with the "choke" lever fully on. It should start normally. If you get the clanking sound, you'll want to order parts for the repair.
Esse veio não pode ter folga?
Hi thanks for the video, can you remember the part number of the replacement sprag kit you used thanks from New Zealand
Hi there! I used KTM#58440026000. Orientation matters. Make sure you install so the locking mechanism works correctly (as shown in the video). Thanks, and I would love to come visit NZ someday. What a beautiful country!
Thanks so much just one more question if you don’t mind how did you align the crank looking tool im paranoid about turning the engine over whilst it’s apart… thanks again
@@Nissankingcabute no problem. I took out the spark plugs and placed a screwdriver in the cylinder. Rotated the engine using the back wheel to the top of the stroke. The divot into which the locking tool fits was fairly simple to find. You could also remove the valve cover and get the timing marks aligned with the cams. My way was fairly straightforward. If it didn’t slot in I backed the tool off a bit rotated the wheel slightly and then tried again. I think it took me two minutes, including trying to sling the wheel with the tool engaged. It WILL NOT turn if you have the tool properly seated.
@@motorcyclemicah6309 thanks 🙏
hello there, Ihave the same problem with my rsv mille 03, can you please tell me the model number of ktm part that fits aprilia rsv 03. thank you so much
58440026000 is the part number. Please double check that the sprags are the same between the year you own and the 99-02 Mille. The second generation RSV uses a completely different part.
sabes cual otra moto es compatible con esa para poder conseguirlo ala mía le.paso lo.mismo
Hi Angel atv,
The parts are compatible with the 1st generation Rotax motor that Aprilia used from 1998-2002 (approximately). That would be the RSV Mille, Tuono, Falco, and Futura models, all of which used the 998cc engine in varying states of tune.
I am not sure on other manufacturers using the same part, however, you might try searching owner’s forums asking them same question. They would more than likely be able to tell you what part numbers you need for a full and complete job.
What ktm sprag clutch do you use mate?
#58440026000. Just be aware that the orientation matters when you put it in. It works great!
Brilliant thanks alot!👍👍
Managed to order thr sprag clutch from ktm now but i cant seem to find an alternative to the aprillia sprag housing. Ive been quoted £190 from aprillia. Also the flywheel itself. Thanks in advance👍
Matty Reid I’m not sure on the housing or flywheel gear. I went with Aprilia parts there. You might keep your eye on eBay in addition to AF1 or Aprilia Performance.
Will it work for 2001 capornd evt
If it has the V990 engine, it will.
How do you find top dead center in the falco? There's no timing mark from what I can see in the flywheel.
Hi there, Austin. I locked the crankshaft by using Aprilia's special tool I referenced int he video. There's a notch it locks into to keep the crankshaft from turning while you apply torque to the flywheel nut. From what I understand, finding TDC will be important for valve clearance checks as this will have the piston at the top (in case a valve falls while you work on it-shouldn't fall all the way in), and there is no compression on the valves for checking. There are timing marks on the cam shaft wheels. I need to check my clearance this winter, and will be doing a video on it.
@@motorcyclemicah6309 sounds like I've gotta either pull the cam cover then, or get an inspection camera down the spark plug hole?
@@MrAustinkocher if you want to find Top Dead center, you will need to pull the cam cover off and line up the timing marks on the cam wheels. I am curious to know how you’re planning on locking the crank shaft down. That’s going to be very important because as you apply torque to the crank shaft bolt, you will turn the crank shaft. And that will mean that you’re not able to fully apply torque to the bolt.
@@MrAustinkocher one more way to find top dead center is to pull a spark plug, and stick a screwdriver into the cylinder. Turn the crank until the screwdriver reaches the top of the stroke.
@@motorcyclemicah6309 I purchased the tdc lock like you have in the video.
what size ktm my bike is needing the samed thing
#58440026000 is the part number. Just be aware that the orientation matters when you put it in. It works great! I would caution about no-name Ebay parts. Make sure you get the actual KTM part. Quality is important here.
Ciao collega ottimo lavoro e ottima manualità bravo e complimenti per il tutorial.
Vorrei chiederti un informazione riguardo alla lunghezza del perno dell'estrattore m22 x 1,5 (minuto 22:37) filettatura destra, ma quanto e lungo?? Circa 50 mm o +?? perché dovrei fare lo stesso lavoro per un Aprilia sl falco 1000 del 2002
Attendo una tua risposta grazie
Saluti dall'Italia 😊
Should be 55.32mm (2.178 inches)
And thank you for the kind words!
You’ll only want to consider this repair if your Falco, Tuono, or Mille one way (“sprag”) clutch begins to fail. If it fails, you’ll hear it. The noise will sound metallic, which is the sound of the starter motor spinning and the clutch not biting on to the flywheel. Mine did this twice, before I put the bike away to learn what I needed to complete the repair. You shouldn’t do the repair if yours is starting fine with no abnormal noises. Thanks for watching and thank you for the question!
@@motorcyclemicah6309 Ciao intanto ti voglio ringraziare per avermi risposto.
Allora sulla mia "falco 1000 V60" e da poco iniziato il così noto problema alla ruota libera i problemi riscontrati sono:
1- rallentamento dell'accensione della moto come se la batteria fosse scarica ma non lo è mi dà circa 12,5 12,7 ma va sotto sforzo comunque all'accensione.
2- qualche volta va in fallo il motorino prima con un crackk e poi si blocca e qualche volta gira a vuoto grrrr grrrr quindi metto la 2° marcia e lo sposto un po' avanti e indietro e riesco a farlo funzionare...
il più evidente e quello dell'accensione debole.
Quindi ho deciso visto che ho un po' di manualità di meccanica di farlo io stesso sono molto sicuro che riesco a farlo senza alcun problema so già che devo scaldare il volano prima dell'estrazione per scomporre la loctite e mettere il blocco albero dal carter opposto m8, non ero sicuro della lunghezza dell'estrattore m22 x 1,5 perché devo ordinarlo su internet e quindi volevo mettermi al sicuro prima di ordinare per non sbagliare.
Non mi resta che ordinare l'estrattore m22 x 1,5 e procedere con l'estrazione del volano, una volta aperto valuterò lo stato di usura del cuscinetto, della flangia, e della ruota dentata e da lì deciderò se sostituire solo alcuni pezzi oppure l'intera ruota libera
@@motorcyclemicah6309 Grazie mille per la tua gentile risposta e ti faccio i miei complimenti per la tua conoscenza e manualità molto professionale. 💯👍👍👍
what ktm model is this from i have the same problem
58440026000 part#
Thank you very much!!
the bearing is from ktm. the gear and the base that screws to the steering wheel are the originals;
Correct! :)
thanks.!! now i will make it for much less money 💪👍