8/3/2019 I-zapp Xv Reseal

1/23

Itsagood

idea

to

identifytheFrontand

Rearcylinderheads

beforestartingthe

teardownprocess.

8/3/2019 I-zapp Xv Reseal

2/23

Usea 17/64drillbit(or6mm

ifyou

have

metric

drills

or

roundstock)tolockthe

camshaftfromturningwhile

looseningthecamsprockets.

8/3/2019 I-zapp Xv Reseal

3/23

Removebothcam

sprocketsusinga

puller.(theyare

NotethattheFRONT

camshaftboltisLH

thread(reverse).

8/3/2019 I-zapp Xv Reseal

4/23

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.

8/3/2019 I-zapp Xv Reseal

5/23

Unscrewthewater

pumpimpellerby

carefullytappingtheimpellerwheel

inacounter

clockwisedirection

hammerandaluminumdrift.A

littleheatcanhelp

toloosenthe

Loctite.

8/3/2019 I-zapp Xv Reseal

6/23

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

.

8/3/2019 I-zapp Xv Reseal

7/23

ThisisasfarastheRHsideof

themotorneedstobebroken

own.

8/3/2019 I-zapp Xv Reseal

8/23

Amusthaveisan

Aprilia

flywheel

puller.

doesNOTcomewithit.

Ifaflywheellocking

too

snot

ava a e,

athinpieceofaluminum

wedgedbetweenthe

crankshaftandclutch

gearsworksjustfineto

lockthe

crank.

8/3/2019 I-zapp Xv Reseal

9/23

Dontforgettoremovethis

.

theonlyonefromRHside

thatholdsthecasehalves

together.

8/3/2019 I-zapp Xv Reseal

10/23

Extendthesleevesoutthecaseaboutaninch.No

fancytoolneeded justturnthecrankshaft

slowlyusingtheflywheelandthefrictionfrom

ringtension

s ou

pus

t em

outwar .

Keep

t e

pistonsnearTDCsotheringsdontpopoutthe

bottomthesleeves.Ifthesleevesarentextended

sufficientl oullnoticethemstuck notloose

whileattemptingtoseparatethecases.

8/3/2019 I-zapp Xv Reseal

11/23

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

8/3/2019 I-zapp Xv Reseal

12/23

on orge o ns a

thedowelandOring

beforerefittingthe

cases.(near

the

starter)

8/3/2019 I-zapp Xv Reseal

13/23

Makesuretheneutral

switchdetentpinisstill

installedbefore

re ng ecases.

8/3/2019 I-zapp Xv Reseal

14/23

Dontforgetthe

sideofthemainshaft.

Itcangetstucktothe

LHcase

when

pulling

t ecasesapart.

8/3/2019 I-zapp Xv Reseal

15/23

TheThreebond1207Bblacksealantis

readilyavailable

through

most

marine

engineshopsforabout$30US.

8/3/2019 I-zapp Xv Reseal

16/23

Alittledabonsealantatthe

bottomofthesleevecounterbores

canthurt.

8/3/2019 I-zapp Xv Reseal

17/23

A

little

smear

of

sealant

at

thesleeve/caseinterfaceis

probablyagoodideatoo.

8/3/2019 I-zapp Xv Reseal

18/23

Modifyaspareboltwitha5/32(or4mm)

holedrilledthroughthecenterofit(usea

.

slippingthe

drill

through

the

bolt

and

into

a

alignmentholeinthecrankshaft.Thisshould

ONLYbeusedfortimingthecamshaft

sproc etsan NOT ortorqueing.

8/3/2019 I-zapp Xv Reseal

19/23

Tosetthecamtiming

drilltolockthecamin

position,andwhilethe

crankshaftislockedin

pos t on,snugupt e

cambolt.

8/3/2019 I-zapp Xv Reseal

20/23

Beforereinstallingthe

waterpumpimpellerwheel,

makesurethewasheris

installedunderneath.

Use

someredLoctiteonthe

itwitheitherastrapwrench

orahammerandaluminum

drift.Excessive

torque

not

requiredsincethewater

pumploadonthewheelis

alwaystighteningit.

8/3/2019 I-zapp Xv Reseal

21/23

Remove,clean,andredLoctitethesesix

screwsunless

already

done.

They

have

a

tendencytobackout.

Installacouplelongscrewswiththeheads

sawedofftoguidethestatorcoverontoLH

side.Themagnetisverystrong,andwithout

thedowelsdamagetothesealinthestator

covercould

result.

8/3/2019 I-zapp Xv Reseal

22/23

Makesurethelittlecollarbetweentheshiftleverandshiftingdrum

doesntfallout(underneaththe

clutchbasket).

8/3/2019 I-zapp Xv Reseal

23/23

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