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Thread: How to guide: crankcase reseal

  1. #1
    apriliaforum Member i-Zapp's Avatar
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    How to guide: crankcase reseal

    The first time through this job was a lengthy ordeal, due to my unfamiliarity with the engine and poor Aprilia documentation. There's quite a few posts on this forum that explain in various detail how to accomplish the job, but as far as i can tell, nothing in a convenient collection.

    So, having to perform the job a SECOND time (dont ask!), i decided to pay it forward and assemble a guide that's meant to SUPPLEMENT the Aprilia service manual. It's meant to just add clarification and tips.

    The entire job took me 6 hours, and i honestly believe that anyone who's serviced the internals of a motorcycle engine should have no problem with it.

    (flickr link removed)

    In .pdf format here:
    http://www.af1racing.com/store/ProdI...v%20reseal.pdf
    Last edited by i-Zapp; 02-20-2011 at 08:24 AM.
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  2. #2
    just another Aprilia fanatic amauri's Avatar
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    Nice work.

    If it is a motor whose history is known to you (like your own bike), this is a very good how-to. The only thing I would add is that further disassembly may be required on a older higher mileage motor.

    Regardless if antifreeze has mixed with the oil, I always replace the rod bearings. Especially on the pre-09 motors that had the stator cover oil seal installed backwards by the factory (that seal feeds oil pressure to the rods) bulletin #008-2008.
    I also chk the valves for wear, inspect the oil pump (especially the 12mm idler gear shaft pressed in the crankcase), chk clutch basket and hone the crankcase mating surfaces.
    Never accept mediocrity, always demand competence.

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  3. #3
    apriliaforum prov-nov gromm415's Avatar
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    that is so cool! i always wondered what it looked like on the inside. thanks for taking the time to put that together.

  4. #4
    apriliaforum expert kimzx1000r's Avatar
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    Nice documentation. Thanks....

  5. #5
    apriliaforum expert ETN550's Avatar
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    Quote Originally Posted by amauri View Post
    Nice work.

    If it is a motor whose history is known to you (like your own bike), this is a very good how-to. The only thing I would add is that further disassembly may be required on a older higher mileage motor.

    Regardless if antifreeze has mixed with the oil, I always replace the rod bearings. Especially on the pre-09 motors that had the stator cover oil seal installed backwards by the factory (that seal feeds oil pressure to the rods) bulletin #008-2008.
    I also chk the valves for wear, inspect the oil pump (especially the 12mm idler gear shaft pressed in the crankcase), chk clutch basket and hone the crankcase mating surfaces.
    I rebuilt an '07 motor and put the new crank seal in "backwards" the way Aprilia had it. Is it ok to use same seal part number and just flip it around on '07 - 08 ?

  6. #6
    just another Aprilia fanatic amauri's Avatar
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    The old original seal has been superceded by the new p/n #855031.

    The bulletin says not to install the old p/n seal in the correct direction (as most of us would think).
    Always use the new p/n and install it in the direction shown in the photo.
    Attached Images Attached Images  
    Never accept mediocrity, always demand competence.

    Certified Aprilia Moto Service in Southern California
    Call me at 714 892-4056 for appointment

  7. #7
    apriliaforum expert soyrico's Avatar
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    Good job!

    One frequent question that comes up about applying sealant to the case halves is how to apply it and where. If you have pic's I think it would be helpful (The "V"). I apply it to one side but I never think about taking pictures during that step because I want to get it sealed quickly.
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  8. #8
    apriliaforum expert Markee's Avatar
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    Good work. This would be great as a sticky, what with Amauri's input as well it makes doing the work yourself a lot less daunting.
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  9. #9
    just another Aprilia fanatic amauri's Avatar
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    Quote Originally Posted by soyrico View Post
    Good job!

    One frequent question that comes up about applying sealant to the case halves is how to apply it and where.
    I use a small acid brush and paint it on lightly on both sides.
    Never accept mediocrity, always demand competence.

    Certified Aprilia Moto Service in Southern California
    Call me at 714 892-4056 for appointment

  10. #10
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    If there are no objections, I will make this a sticky...
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    direct:830-626-3966 fax:830-626-3969

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  11. #11
    apriliaforum Member i-Zapp's Avatar
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    ... the only suggestion i have is that the images be moved/copied to this server to insure their availability long term. i can convert the whole thing into a single PDF file and upload it, but i think i will need more than the 244kb limit for that file.
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    "The key to life is to die young. And to delay it as long as possible."

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  13. #13
    just another Aprilia fanatic amauri's Avatar
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    Quote Originally Posted by i-Zapp View Post
    ... the only suggestion i have is that the images be moved/copied to this server to insure their availability long term.
    another good idea
    Never accept mediocrity, always demand competence.

    Certified Aprilia Moto Service in Southern California
    Call me at 714 892-4056 for appointment

  14. #14
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Quote Originally Posted by i-Zapp View Post
    ... the only suggestion i have is that the images be moved/copied to this server to insure their availability long term. i can convert the whole thing into a single PDF file and upload it, but i think i will need more than the 244kb limit for that file.
    If you're comfortable with it, you can email the oversize .pdf to me (steveataf1racingdotcom) and I can upload it to our server, and link to it in this thread.
    AF1 Racing, inc / ApriliaForum.com
    699 W San Antonio St
    New Braunfels, TX 78130

    direct:830-626-3966 fax:830-626-3969

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

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    apriliaforum expert SXVINWA's Avatar
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    Quote Originally Posted by i-Zapp View Post
    ... the only suggestion i have is that the images be moved/copied to this server to insure their availability long term. i can convert the whole thing into a single PDF file and upload it, but i think i will need more than the 244kb limit for that file.


    Converted it Sunday for my own use! File size ended up being just under 4M with the large images.

    Also... instead of creating another sticky, why not just add this to the existing "How to" thread?

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