I-zapp Xv Reseal
Transcript of I-zapp Xv Reseal
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Itsagood
idea
to
identifytheFrontand
Rearcylinderheads
beforestartingthe
teardownprocess.
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Usea 17/64drillbit(or6mm
ifyou
have
metric
drills
or
roundstock)tolockthe
camshaftfromturningwhile
looseningthecamsprockets.
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Removebothcam
sprocketsusinga
puller.(theyare
NotethattheFRONT
camshaftboltisLH
thread(reverse).
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Toremovetheheads and
reinstall)youllneeda14mm
swivelsocket(short6point,
withbuilt
in
universal
joint)
oaccess e o en
underthecamshaft.No
needtoremovecams.
Torqueingthat
bolt
is
tricky,
aswellastheotherexternal
boltthatsblockedbythe
.
pullyoucanuseaboxend
combinationwrench.
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Unscrewthewater
pumpimpellerby
carefullytappingtheimpellerwheel
inacounter
clockwisedirection
hammerandaluminumdrift.A
littleheatcanhelp
toloosenthe
Loctite.
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whatApriliacallsa
transmissionshaft
andservesasa
ac s a t etween
thecrank
and
camshafts.Alittle
heatherecanbe
helpfultoloosenthe
Loctiteonthenut.
Removalof
the
gear
can e cu oo
Loctitehasgotten
betweenthegear
andshaft,sosome
carefulheat
applicationmaybe
requiredtoliberate
.
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ThisisasfarastheRHsideof
themotorneedstobebroken
own.
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Amusthaveisan
Aprilia
flywheel
puller.
doesNOTcomewithit.
Ifaflywheellocking
too
snot
ava a e,
athinpieceofaluminum
wedgedbetweenthe
crankshaftandclutch
gearsworksjustfineto
lockthe
crank.
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Dontforgettoremovethis
.
theonlyonefromRHside
thatholdsthecasehalves
together.
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Extendthesleevesoutthecaseaboutaninch.No
fancytoolneeded justturnthecrankshaft
slowlyusingtheflywheelandthefrictionfrom
ringtension
s ou
pus
t em
outwar .
Keep
t e
pistonsnearTDCsotheringsdontpopoutthe
bottomthesleeves.Ifthesleevesarentextended
sufficientl oullnoticethemstuck notloose
whileattemptingtoseparatethecases.
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7mmbolt
thats
capturedbythe
clutchreleaselever.
Unscrewbutleave
np ace.
Tip:useapaintpen
bolthead.Makesit
easiertoidentify
theselarger
size
bolts
Largealuminum
boltfromEi ht 6mm from the
w entorqueingt em
later.
One7mm
fromtheRH
underneaththe
neutralswitch.
LHsideF ve
7mm
rom
t e
LHside(plusone
above)
side
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on orge o ns a
thedowelandOring
beforerefittingthe
cases.(near
the
starter)
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Makesuretheneutral
switchdetentpinisstill
installedbefore
re ng ecases.
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Dontforgetthe
sideofthemainshaft.
Itcangetstucktothe
LHcase
when
pulling
t ecasesapart.
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TheThreebond1207Bblacksealantis
readilyavailable
through
most
marine
engineshopsforabout$30US.
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Alittledabonsealantatthe
bottomofthesleevecounterbores
canthurt.
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A
little
smear
of
sealant
at
thesleeve/caseinterfaceis
probablyagoodideatoo.
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Modifyaspareboltwitha5/32(or4mm)
holedrilledthroughthecenterofit(usea
.
slippingthe
drill
through
the
bolt
and
into
a
alignmentholeinthecrankshaft.Thisshould
ONLYbeusedfortimingthecamshaft
sproc etsan NOT ortorqueing.
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Tosetthecamtiming
drilltolockthecamin
position,andwhilethe
crankshaftislockedin
pos t on,snugupt e
cambolt.
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Beforereinstallingthe
waterpumpimpellerwheel,
makesurethewasheris
installedunderneath.
Use
someredLoctiteonthe
itwitheitherastrapwrench
orahammerandaluminum
drift.Excessive
torque
not
requiredsincethewater
pumploadonthewheelis
alwaystighteningit.
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Remove,clean,andredLoctitethesesix
screwsunless
already
done.
They
have
a
tendencytobackout.
Installacouplelongscrewswiththeheads
sawedofftoguidethestatorcoverontoLH
side.Themagnetisverystrong,andwithout
thedowelsdamagetothesealinthestator
covercould
result.
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Makesurethelittlecollarbetweentheshiftleverandshiftingdrum
doesntfallout(underneaththe
clutchbasket).
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Generalnotes
Special
tools
and
materials
needed Apriliaflywheelpuller9100839,andM16x2.0bolt
RedLoctite
Threebondsealer1207B(Google0351053forSuzukisealer)
14mm6pointswivelsocketforheadbolts
5/32drill
for
crankshaft
timing
alignment
15/64drillforcamshafttimingalignment
2jawgearpuller
Goodtorquewrenchesfor10Nm 110Nmrange
Additionalrecommendedprocedures
Goodpracticetocompletelydisassembleengine
Measurecylindersleeveprotrusion,0.0000.004
Lapcasehalves withsome500gritsandpaperonasurfaceplatetoinsureflatness
ThoroughlycleancasesealingsurfaceswithcontactcleaneroralcoholandcoatentireRH
casematingsurfacewithThreebondusingsmallbrush.
Replacerodormainbearingsiftheresanysignofdistressorcorrosion
Checksealorientationinthestatorcover(lipshouldbeoninsideofcover)
ContactiZapp
at
ApriliaForum.com for
corrections
/
changes