Serwisówka AM6 pełna.pdf

Workshop manual

AM6

970 X

LIST OF SECTIONS

Introduction

This manual provides basic information on standard

servicing procedures. The data and illustrations con-

tained in the manual were up to date at the moment

of publication.

Owing to aprilia ’s constant commitment to improv-

ing the quality and performance of its products, vehi-

cles are subject to change without notice. Users of

this publication should consequently be aware that,

for some models, the information provided may not

be entirely up to date.

Updates of specifications and servicing procedures

resulting from changes made to vehicles will be noti-

fied to all aprilia distributors, who will in turn make

them available to after-sales mechanics.

Before performing any operation, ensure that the in-

formation contained in this manual is applicable to

the vehicle to be serviced.

This publication is meant for aprilia dealers and their

trained and qualified mechanics. The description of

many service and repair operations has been delib-

erately omitted in that it is assumed that users of this

manual have received a basic training in mechanics,

that they are aware of vehicle repairing techniques,

and that they have at their disposal all the informa-

tion published by aprilia on the vehicle. Should any

of these three conditions not be fulfilled, repairs and/

or servicing may prove inadequate and thereby re-

sult in danger or injury.

This manual does not provide a detailed description

of all the procedures required to perform repairs and

servicing operations. It is therefore essential to exer-

cise extreme caution in order to prevent damage to

the vehicle and its components as well as personal

injury to mechanics and the user.

General Information

General Specifications

Power plant

Carburettor - Oil Mixer

Flywheel Magneto

Starter Motor

Gearbox, Clutch and Water Pump

In case of doubt as to the repairing or servicing pro-

cedures, please contact aprilia’s AFTER-SALES DE-

PARTMENT: aprilia ’s technicians will be pleased to

provide all necessary support.

First release: January 2000

Designed and printed by:

CLD s.r.l Technical Manuals Department

Via Dante Alighieri, 37/A – 56012 Fornacette (Pisa) -

Italy

Tel. +39 0587 422800

Fax +39 0587 422801

www.cld.it

E-mail: cld@cld.it

For further information, please refer to:

– THE CYCLE PARTS WORKSHOP MANUAL

– THE ENGINE SPARE PARTS CATALOGUE

– THE CHASSIS SPARE PARTS CATALOGUE

aprilia reserves the right to make any changes at any moment to all

its models.

This manual is copyright worldwide. Any reproduction thereof in printed

or electronic form is forbidden.

The mention of third parties’ products is only made for information

purposes, and constitutes no engagement.

aprilia assumes no responsibility for the use of products it has not

expressly recommended or approved.

for:

aprilia S.p.A.

Via G. Galilei, 1 – 30033 Noale (VE) – Italy

Tel. +39 041 5829111

Fax +39 041 441054

www.aprilia.com

www.serviceaprilia.com

General Information

AM6

CONTENTS

Chapter 1

Introduction ............................................................................................................................... 1-1

Contents ............................................................................................................................. 1-2, 1-3

SAFETY PRECAUTIONS ......................................................................................................... 1-4

RECOMMENDATIONS ON MAINTENANCE ........................................................................... 1-4

GENERAL SAFETY RULES ..................................................................................................... 1-5

CARBON MONOXIDE .............................................................................................................. 1-5

FUEL ......................................................................................................................................... 1-6

GEARBOX OIL .......................................................................................................................... 1-6

COOLANT ................................................................................................................................. 1-6

Chapter 2

Tightening torques ..................................................................................................................... 2-2

Table of lubricants ..................................................................................................................... 2-3

Ignition timing ............................................................................................................................ 2-3

Tools .......................................................................................................................................... 2-4

Chapter 3

Removing the cylinder head ...................................................................................................... 3-2

Removing the thermostat .......................................................................................................... 3-2

Removing the cylinder ............................................................................................................... 3-2

Removing the piston ................................................................................................................. 3-3

Checking the power plant .......................................................................................................... 3-3

Checking the thermostat ........................................................................................................... 3-5

Checking the gasket seats ........................................................................................................ 3-5

Refitting the power plant ........................................................................................................... 3-5

Chapter 4

Removing the intake manifold ................................................................................................... 4-2

Checks ...................................................................................................................................... 4-2

Removing the carburettor .......................................................................................................... 4-2

Removing the reed valve unit .................................................................................................... 4-2

Fitting the reed valve unit .......................................................................................................... 4-3

Fitting the carburettor ................................................................................................................ 4-3

Checks ...................................................................................................................................... 4-4

Removing the oil mixer .............................................................................................................. 4-4

Fitting the oil pump .................................................................................................................... 4-5

Chapter 5

Removing the stator .................................................................................................................. 5-2

Removing the flywheel cover .................................................................................................... 5-2

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AM6

Removing the flywheel ............................................................................................................. 5-2

Flywheel checks ....................................................................................................................... 5-3

Fitting the flywheel ................................................................................................................... 5-3

Removing the starter motor ...................................................................................................... 5-4

Fitting the flywheel cover .......................................................................................................... 5-4

Fitting the starter motor ............................................................................................................ 5-5

Chapter 6

Removing the water pump ....................................................................................................... 6-2

Removing the clutch cover ....................................................................................................... 6-2

Removing the pinion ................................................................................................................ 6-3

Disassembling the clutch ......................................................................................................... 6-3

Removing the countershaft ...................................................................................................... 6-4

Clutch control lever .................................................................................................................. 6-5

Disassembling the crankcase .................................................................................................. 6-5

Removing the drive pinion ........................................................................................................ 6-5

Countershaft disassembly ........................................................................................................ 6-6

Removing the selector shaft ..................................................................................................... 6-6

Removing the driven shaft ....................................................................................................... 6-6

Removing the driving shaft ....................................................................................................... 6-7

Removing the crankshaft ......................................................................................................... 6-7

Preliminary operations ............................................................................................................. 6-8

Checking the connecting rod and flywheel ............................................................................... 6-8

Disassembly of driven and driving shaft gears ......................................................................... 6-9

Reassembly of driven and driving shaft gears ......................................................................... 6-9

Checking the end play .............................................................................................................. 6-9

Checking the gear shaft ........................................................................................................... 6-9

Checking the desmodromic shaft ........................................................................................... 6-10

Checking the selector shaft .................................................................................................... 6-10

Checking the clutch ................................................................................................................ 6-10

Checking the gear shaft bearings .......................................................................................... 6-10

Fitting the countershaft ........................................................................................................... 6-11

Assembling the transmission components ............................................................................. 6-11

Assembling the selector unit .................................................................................................. 6-11

Fitting the connecting rod assembly ....................................................................................... 6-12

Checking the gear shaft operation ......................................................................................... 6-12

Assembling the crankcase ..................................................................................................... 6-13

Fitting the oil seals on the driven and selector shafts ............................................................ 6-13

Assembling the gear and pinion ............................................................................................. 6-13

Assembling the clutch ............................................................................................................ 6-14

Fitting the countershaft gear .................................................................................................. 6-14

Checking the clutch position .................................................................................................. 6-15

Fitting the clutch cover parts .................................................................................................. 6-15

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General Information

AM6

SAFETY PRECAUTIONS

The following symbols are used in the manual to stress the importance of certain pieces of information:

: This symbol is used when special precautions are needed in dangerous situations that can

cause death or serious injury to the operator and other exposed people, or result in serious and permanent

damage to the vehicle.

: This symbol denotes a potentially hazardous situation that may result in minor personal

injury or damage to the vehicle.

IMPORTANT: This term precedes important information or instructions that deserve special attention.

RECOMMENDATIONS ON MAINTENANCE

IMPORTANT: Always observe the following precautions when repairing, fitting or removing engine compo-

nents.

: All engine inspections and maintenance operations must be carried out while the engine is

switched off. Also ensure that no parts (such as the silencer, the brakes and other components that are

subject to heating) are hot after removing the engine from the vehicle. If necessary, wait for all parts to cool

down. Use suitable equipment to support the engine, taking care to place it on a level and solid working

surface.

: Do not hold mechanical parts or engine components in the mouth, as some of them are made

of toxic materials.

DANGER

: Avoid starting the engine in closed or poorly ventilated rooms.

DANGER

: Keep away from heat sources. Do not use bright flames.

IMPORTANT: Operators servicing or repairing the engine must have all operating instructions to hand and

follow them scrupulously while observing the safety precautions prescribed for each part (e.g. tightening

torques). When two or more operators are required to work on the same engine at the same time, all of

them must observe the rules that ensure their own safety and that of others.

Only use GENUINE aprilia spares.

Avoid using lubricants other than those shown in the table on page 2-3.

Always use the special tools that are prescribed in this manual. Never attempt to perform operations that require

the use of special equipment with tools other than those specified in this manual.

: Failure to comply with the above instructions can result in serious personal injury, as is the

case when an unsuitable spanner slips off a fastening device, causing the operator’s hand to strike against

the workbench.

When clamping fastening devices, always begin with the largest ones. Apply sufficient torque to tighten

each of the large-diameter fasteners, starting with the innermost device, and then proceeding diagonally.

Following the same order, clamp the fastening devices with the prescribed torques, and then check the

torque value for each of the fasteners.

: Never use flammable solvents to clean the parts. Only use antifire detergents and solvents.

Failure to observe this precaution may result in a fire breaking out and in serious or even fatal personal

injury.

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DANGER

CAUTION

DANGER

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