How to guide: crankcase reseal

[SIR REAL ED]

I use a small acid brush and paint it on lightly on both sides.

Are the mating surfaces of the two crankcase halves the only place the sealant is applied?

I have seen some posts about decking the heads or lapping the heads. Is sealant applied anywhere on the head or crankcase mating surfaces or once the heads are flat, are the gaskets sufficient?

This post is directed at all who have opinions, not just amauri.

Thanks.

[i-Zapp]

ok, i've emailed steve the PDF file. expect he'll post a reply with the link once he uploads it. i also added some additional wisdom from others on this thread.

[Steve / AF1 Racing]

ok, i've emailed steve the PDF file. expect he'll post a reply with the link once he uploads it. i also added some additional wisdom from others on this thread.

Linked here:

http://www.af1racing.com/store/ProdI...v%20reseal.pdf

Thanks again to i-Zapp. This will doubtless be consulted many, many, times.

[RXV2SXV450]

Thanks i-Zapp you have lifted the veil of remorse for purchasing a 07 RXV 450

[Paizan]

Awesome i-Zapp. I wish I had your little tips 2 months ago. I took everything apart per the service manual. Got to the Primary gear and before I took it off, saw this thread and didn't have to. (Yes, been disasembleing for 2 months, I work too much) I do have some questions but I am going to post those in another thread as to not clutter this up. Excellent job! I can always count on this forum to get my answers.

In fact, if given the option of listening to my dealer tech or anyone on Apriliaforum, it's a no brainer. This place rules!!

[colo_rider]

This is absolutely great. I now know why my dealer is not so eager to work on my RXV450 before getting Aprilia warrantee approval. And if they don't do it, I may have to. So, once again the power of this forum shows. Thanks!

[Darth Vader]

Before resealing housings, it is desirable to check and prepare the sealing surfaces. If the sealing surface is not flat enough, problem will come back sooner or later.... After many resealed Aprilias I found that the proper flattening is one of the crucial facts of the successful fixing oil-water mixing issue. For that purpose, I’m using 500x350x45 mm grinded cast iron plate and coarse grinding paste. That procedure fixing small irregularity on the surfaces...Similar procedure has been described in a factory warranty claim.
Pictures showing surfaces after described procedure... I done it today on one burned engine...
Most critical, and cause of the oil-water mixing is triangle area between cylinders...Of course cylinders and housings have to be preassembled and grinded together...

[mechcanico lee]

Good pictures darth vader, just to add if you havent got use of a cast iron grinding plate you can use 8mm guage or thicker pane of glass available from most glass makers/cutters outlets

[Darth Vader]

Good pictures darth vader, just to add if you havent got use of a cast iron grinding plate you can use 8mm guage or thicker pane of glass available from most glass makers/cutters outlets

Thanks, and beside mine Motorcycle Mechanic trade, I'm also a Toolmaker, so I prefer iron

[Sneaky Aprilia]

same topic. What would you guys think my motor needs? i have an 08 sxv 550 6k miles and runs fine valve clearance has been ck, but do i really need to break it down? is the motor guna granade? thanks for your advise

[Darth Vader]

same topic. What would you guys think my motor needs? i have an 08 sxv 550 6k miles and runs fine valve clearance has been ck, but do i really need to break it down? is the motor guna granade? thanks for your advise

simply,

if it isn't faulty, don't fix it ...

but pay attention on well known oil-water issue

[Thund3r]

Threebond 1207D
Will this sealant work?

[Darth Vader]

Threebond 1207D
Will this sealant work?

I am useing this one
http://www.techsilonline.com/getatta...Tech-Data.aspx
it is recommended by Aprilia, and I can say it is the best I have ever tried... Keep it in the fridge...

[TMac]

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.

Yesterday I took delivery of a new '08 SXV. Before deciding to buy I spent a fair amount of time and effort in research and asking questions and concluded that the '08 was clear of issues (ex: orange sealant). I may not have spent enough time though because I missed this "reverse seal" issue.

I have not yet started this motor...should i correct the seal before doing so? Can this be done without major engine disassembly? Are there other issues that I should be aware of? Thanks!

[JDS550]

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.

Is there a specific(upgraded/better) bearing's to be used as a replacement?