APRILIA 8140172, Service And Repair Manual

Page: 85 / 279

ENGINE
3
3 - 2
RSV mille
ENGINE
4!",% /& #/.4%.43
4%#(.)#!, ).&/2-!4)/.
.......................... 3-3
3.1.1 TECHNICAL DATA ....................................... 3-3
3.1.2 MAINTENANCE INTERVALS ....................... 3-3
3.1.3 TROUBLESHOOTING ................................... 3-3
3.1.4 SEALANTS .................................................... 3-3
3.1.5 LUBRICANTS ................................................ 3-3
3.1.6 SPECIAL TOOLS
&
.................................... 3-3
3.1.7 DRIVING TORQUE ........................................ 3-3
3.1.8 PRECONDITIONS TO BE MET
WHEN PERFORMING MAINTENANCE
AND REPAIR WORK ..................................... 3-3
3.1.9 GENERAL INDICATIONS
ON MAINTENANCE AND REPAIR WORK ... 3-3
%.').% 0!243 7()#( #!. "%
$)3!33%-",%$ 7)4(/54 2%-/6).'
4(% %.').% &2/- 4(% &2!-%
............. 3-4
3.2.1 REMOVING THE EXHAUST PIPES .............. 3-6
3.2.2 REMOVING THE GEARSHIFT PEDAL ........ 3-7
3.2.3 REMOVING
THE CLUTCH CONTROL CYLINDER .......... 3-7
2%-/6).' 4(% 7(/,% %.').%
&2/- 4(% &2!-%
...................................... 3-8
2%&)44).' 4(% 7(/,% %.').%
/. 4(% &2!-%
........................................... 3-17
$)3!33%-",).' 4(% %.').%
............... 3-18
3.5.1 ENGINE DISASSEMBLY SEQUENCE ....... 3-18
3.5.2 REMOVING THE STARTER MOTOR ......... 3-20
3.5.3 DISASSEMBLING CYLINDER “1” (FRONT),
HEAD AND PISTON .................................... 3-20
3.5.4 DISASSEMBLING CYLINDER “2” (REAR),
HEAD AND PISTON .................................... 3-23
3.5.5 REMOVING THE FLYWHEEL COVER
AND IGNITION SYSTEM ............................. 3-26
3.5.6 DISASSEMBLING CYLINDER “1” (FRONT)
TIMING DRIVE ASSEMBLY ........................ 3-27
3.5.7 REMOVING THE DRIVING CHAIN PINION
AND OIL FILTER CARTRIDGE................... 3-28
3.5.8 REMOVING THE CLUTCH COVER............ 3-29
3.5.9 DISASSEMBLING THE CLUTCH ............... 3-30
3.5.10 DISASSEMBLING
THE COUNTERSHAFT MECHANISM
AND PRIMARY TRANSMISSION ............. 3-31
3.5.11 DISASSEMBLING CYLINDER “2”
(REAR) TIMING DRIVE ASSEMBLY ........ 3-32
3.5.12 DISASSEMBLING THE OIL PUMP........... 3-33
3.5.13 DISASSEMBLING THE GEAR
SELECTION MECHANISM........................ 3-34
3.5.14 SPLITTING THE ENGINE CASING OPEN 3-35
3.5.15 DISASSEMBLING THE
DRIVING SHAFT AND COUNTERSHAFT 3-35
3.5.16 DISASSEMBLING THE GEARSHIFT ....... 3-36
7/2+ /. 4(% ).$)6)$5!, 0!243
...... 3-37
3.6.1 ENGINE CASING ........................................ 3-37
3.6.2 ENGINE HALF-CASING, CLUTCH SIDE ... 3-38
3.6.3 ENGINE HALF-CASING, FLYWHEEL SIDE. 3-38
3.6.4 ENGINE HALF-CASING -
BALL BEARINGS AND OIL SEALS ........... 3-39
3.6.5 ENGINE HALF-CASING - MAIN BUSHES,
DRIVING SHAFT AND COUNTERSHAFT .. 3-41
3.6.6 REPLACING THE ENGINE CASING
CYLINDRICAL PINS.................................... 3-45
3.6.7 NEUTRAL GEAR INDICATION................... 3-46
3.6.8 ASSEMBLING THE ENGINE HALF-CASING 3-46
3.6.9 COMPLETE OIL-SPRAY PIPE ................... 3-46
3.6.10 OIL PUMP AND OIL PUMP DRIVE
ASSEMBLY ............................................... 3-47
3.6.11 DRIVING SHAFT ....................................... 3-49
3.6.12 DISASSEMBLING
THE CONNECTING RODS........................ 3-50
3.6.13 REPLACING AND INSTALLING
THE CONNECTING RODS ....................... 3-51
3.6.14 COUNTERSHAFT AND
COUNTERSHAFT MECHANISM .............. 3-52
3.6.15 GEARSHIFT .............................................. 3-53
3.6.16 GEAR SELECTION ................................... 3-58
3.6.17 CLUTCH AND PRIMARY
TRANSMISSION ASSEMBLY................... 3-59
3.6.18 DISASSEMBLING
THE COMPLETE CLUTCH HOUSING ..... 3-61
3.6.19 CLUTCH COVER ...................................... 3-62
3.6.20 SUPPORT BUSHES.................................. 3-62
3.6.21 COOLANT PUMP...................................... 3-64
3.6.22 TIMING DRIVE ASSEMBLY ..................... 3-66
3.6.23 HEAD AND CAMSHAFT........................... 3-67
3.6.24 DISASSEMBLING
THE INTAKE AND EXHAUST VALVES ... 3-68
3.6.25 CAMSHAFT AND CAMSHAFT BUSHES. 3-69
3.6.26 UPPER COUNTERSHAFT........................ 3-70
3.6.27 DISASSEMBLING AND ASSEMBLING
THE UPPER COUNTERSHAFT
BALL BEARINGS AND OIL SEAL ........... 3-71
3.6.28 VALVE GUIDE........................................... 3-72
3.6.29 VALVES..................................................... 3-74
3.6.30 CYLINDER................................................. 3-77
3.6.31 PISTON AND GUDGEON PIN .................. 3-78
3.6.32 STARTER MOTOR DRIVE ASSEMBLY... 3-80
3.6.33 IGNITION GENERATOR ........................... 3-82
3.6.34 SPARK PLUGS ......................................... 3-84
3.6.35 DRIVING CHAIN PINION .......................... 3-84
3.6.36 STARTER MOTOR.................................... 3-84
2%!33%-",).' 4(% %.').%
................ 3-85
3.7.1 ASSEMBLING THE GEARSHIFT ............... 3-85
3.7.2 ASSEMBLING THE DRIVING SHAFT
AND COUNTERSHAFT............................... 3-86
3.7.3 ASSEMBLING THE ENGINE CASING ....... 3-87
3.7.4 ASSEMBLING THE GEAR SELECTION
MECHANISM ............................................... 3-88
3.7.5 CHECKING THE GEAR SELECTION
MECHANISM ............................................... 3-89
3.7.6 ASSEMBLING THE OIL PUMP .................. 3-90
3.7.7 ASSEMBLING THE DRIVE ASSEMBLY
“2” (REAR) .................................................. 3-91
3.7.8 ASSEMBLING
THE COOLANT PUMP DRIVE .................... 3-93
3.7.9 ASSEMBLING THE PRIMARY
TRANSMISSION AND CLUTCH ................. 3-94
3.7.10 ASSEMBLING THE PISTON AND
CYLINDER “2” (REAR)............................. 3-96
3.7.11 ADJUSTING VALVE CLEARANCE.......... 3-99
3.7.12 ASSEMBLING HEAD “2” (REAR)
CAMSHAFT ............................................. 3-100
3.7.13 ASSEMBLING HEAD “2” (REAR)
TIMING DRIVE ASSEMBLY.................... 3-101
3.7.14 ASSEMBLING HEAD “1” TIMING
DRIVE ASSEMBLY ................................. 3-103
3.7.15 ASSEMBLING
THE STARTER MOTOR DRIVE
ASSEMBLY AND IGNITION SYSTEM.... 3-105
3.7.16 ASSEMBLING THE PISTON AND
CYLINDER “1” (FRONT) ........................ 3-106
3.7.17 ASSEMBLING HEAD “1” (FRONT)
CAMSHAFT ............................................. 3-109
3.7.18 ASSEMBLING HEAD “1” (FRONT)
TIMING DRIVE ASSEMBLY.................... 3-110
3.7.19 ASSEMBLING THE VALVE COVER ...... 3-111
3.7.20 ASSEMBLING THE IGNITION COVER .. 3-112
3.7.21 ASSEMBLING THE CLUTCH HOUSING 3-113
3.7.22 ASSEMBLING THE STARTER MOTOR 3-115
3.7.23 ASSEMBLING
THE DRIVING CHAIN PINION ................ 3-115
%.').% #(%#+3 35"3%15%.4
4/ 2%!33%-",9
...................................... 3-116
3.8.1 BLEEDING THE ENGINE OIL CIRCUIT ... 3-116
3.8.2 CHECKING
THE ENGINE OIL PRESSURE.................. 3-116
3.8.3 SYNCHRONIZING CYLINDERS ............... 3-116