Itsagoodideato identifytheFrontand Rearcylinderheads usingapaintpen using a paint pen beforestartingthe teardownprocess.

Usea17/64drillbit(or6mm ifyouhavemetricdrillsor roundstock)tolockthe camshaftfromturningwhile looseningthecamsprockets.

Removebothcam sprocketsusinga puller.(theyare taperedfit) tapered fit) NotethattheFRONT camshaftboltisLH thread(reverse).

Toremovetheheads(and ( reinstall)youllneeda14mm swivelsocket(short6point, withbuiltinuniversaljoint) toaccessthebolthidden to access the bolt hidden underthecamshaft.No needtoremovecams. Torqueingthatboltistricky, aswellastheotherexternal boltthatsblockedbythe camshaft.Ifyoutrustyour camshaft If you trust your pullyoucanuseaboxend combinationwrench.

Unscrewthewater pumpimpellerby carefullytapping theimpellerwheel inacounter clockwisedirection (RHthread)witha (RH thread) with a hammerand aluminumdrift.A littleheatcanhelp toloosenthe Loctite.

Thelargegearis The large gear is whatApriliacallsa transmissionshaft andservesasa jackshaftbetween kh f b thecrankand camshafts.Alittle heatherecanbe helpfultoloosenthe Loctiteonthenut. Removalofthegear canbedifficulttooif b diffi lt t if Loctitehasgotten betweenthegear andshaft,sosome carefulheat applicationmaybe requiredtoliberate thegear. the gear

ThisisasfarastheRHsideof themotorneedstobebroken down.

Amusthaveisan Apriliaflywheelpuller. TheM16x2drawbolt The M16x2 draw bolt doesNOTcomewithit. Ifaflywheellocking toolisnotavailable,a li il bl thinpieceofaluminum wedgedbetweenthe crankshaftandclutch gearsworksjustfineto lockthecrank.

Dontforgettoremovethis boltfromtheRHside.It s bolt from the RH side Its theonlyonefromRHside thatholdsthecasehalves together.

Extendthesleevesoutthecaseaboutaninch.No fancytoolneeded justturnthecrankshaft slowlyusingtheflywheelandthefrictionfrom ringtensionshouldpushthemoutward.Keepthe h ld h h d h pistonsnearTDCsotheringsdontpopoutthe bottomthesleeves.Ifthesleevesarentextended y, y ( ) sufficiently,youllnoticethemstuck(notloose) whileattemptingtoseparatethecases.

7mmboltthats capturedbythe clutchreleaselever. Unscrewbutleave inplace. in place Tip:useapaintpen toidentifyeach7mm to identify each 7mm bolthead.Makesit easiertoidentify theselargersizebolts whentorqueingthem h h later. Five7mmfromthe Fi 7 f h LHside(plusone above) Eight6mmfromthe Eight 6mm from the LHside Largealuminum boltfrom underneaththe neutralswitch.

One7mm fromtheRH side

Dontforgettoinstall Dont forget to install thedowelandOring beforerefittingthe cases.(nearthe starter)

Makesuretheneutral switchdetentpinisstill installedbefore refittingthecases. fitti th

Dontforgetthe washerontheLH washer on the LH sideofthemainshaft. Itcangetstucktothe LHcasewhenpulling thecasesapart. th t

TheThreebond1207Bblacksealantis readilyavailablethroughmostmarine engineshopsforabout$30US.

Alittledabonsealantatthe bottomofthesleevecounterbores canthurt.

Alittlesmearofsealantat thesleeve/caseinterfaceis probablyagoodideatoo.

Modifyaspareboltwitha5/32(or4mm) holedrilledthroughthecenterofit(usea lathe).Lockthecrankshaftpositionby lathe) Lock the crankshaft position by slippingthedrillthroughtheboltandintoa alignmentholeinthecrankshaft.Thisshould ONLYbeusedfortimingthecamshaft sprocketsandNOTfortorqueing. k d O f i

Tosetthecamtiming usea15/64 (or 6mm) use a 15/64(or6mm) drilltolockthecamin position,andwhilethe crankshaftislockedin position,snugupthe iti th cambolt.

Se Se

Beforereinstallingthe waterpumpimpellerwheel, makesurethewasheris installedunderneath.Use someredLoctiteonthe impellerwheelandtighten impeller wheel and tighten itwitheitherastrapwrench orahammerandaluminum drift.Excessivetorquenot requiredsincethewater pumploadonthewheelis alwaystighteningit.

Remove,clean,andredLoctitethesesix screwsunlessalreadydone.Theyhavea tendencytobackout.

Installacouplelongscrewswiththeheads sawedofftoguidethestatorcoverontoLH side.Themagnetisverystrong,andwithout thedowelsdamagetothesealinthestator covercouldresult.

Makesurethelittlecollarbetween theshiftleverandshiftingdrum ( doesntfallout(underneaththe clutchbasket).

Generalnotes
Specialtoolsandmaterialsneeded p
Apriliaflywheelpuller9100839,andM16x2.0bolt RedLoctite Threebondsealer1207B(Google0351053forSuzukisealer) 14mm6pointswivelsocketforheadbolts 5/32drillforcrankshafttimingalignment 15/64drillforcamshafttimingalignment M8boltwith5/32 hole drilled through the center M8 bolt with 5/32holedrilledthroughthecenter 2jawgearpuller Goodtorquewrenchesfor10Nm 110Nmrange

Additionalrecommendedprocedures
Goodpracticetocompletelydisassembleengine
Measurecylindersleeveprotrusion,0.0000.004 Lapcasehalveswithsome500gritsandpaperonasurfaceplatetoinsureflatness

ThoroughlycleancasesealingsurfaceswithcontactcleaneroralcoholandcoatentireRH casematingsurfacewithThreebondusingsmallbrush. Replacerodormainbearingsiftheresanysignofdistressorcorrosion p g y g Checksealorientationinthestatorcover(lipshouldbeoninsideofcover) ContactiZappatApriliaForum.com forcorrections/changes