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Thread: Caponord 1200 Rally - Front Cylinder Timing Gear

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  1. #1
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    Caponord 1200 Rally - Front Cylinder Timing Gear Noise

    Only 3000 kms (2000 miles)

    https://youtu.be/HEvi9akWDdQ

    They should issue the recall... also its extremelly hard to remove all the necessary to get the gear off the bike...
    Last edited by aleib; 11-28-2017 at 01:38 PM.

  2. #2
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    Did you replace the gear yourself? How difficult and complex was it?
    [COLOR=inherit !important]


    [/COLOR]

  3. #3
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    What year is your bike?

  4. #4
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    the most critical step is to keep timing... is a great idea to block the engine (form th estator side) and use the guides.

    any bit of 3mm x 10cm metal put in the cams will do the job perfectly... but do not rotate the engine on error (basically step 16) or you will be lost in the sea...

    I only recommend this procedure for persons with a lot of experience and patience... we are talking over 100 nuts/fasteners and alot of order and registration with phonos must be done all the time... at some point nerve-crisis is possible, so better have enougth time and do not push anything.

  5. #5
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    Quote Originally Posted by aleib View Post
    the most critical step is to keep timing... is a great idea to block the engine (form th estator side) and use the guides.

    any bit of 3mm x 10cm metal put in the cams will do the job perfectly... but do not rotate the engine on error (basically step 16) or you will be lost in the sea...

    I only recommend this procedure for persons with a lot of experience and patience... we are talking over 100 nuts/fasteners and alot of order and registration with phonos must be done all the time... at some point nerve-crisis is possible, so better have enougth time and do not push anything.
    My repair took two days by a very competent pro mechanic. This repair is not DIY frendly. The cams need to be marked before removal! The other pita is retracting the cam chain tensioner when reassembling the cam chain to the drive gear. Magic marker every thing that needs to keep the timing correct. You will need both the service manual and the parts manual in order to stay organized.
    Really, by the time you gain access to the cylinder heads, you will have removed a lot of major components. In particular be sure the electrical connections are securely replaced. Aprilia service center in California provided the special tools that keep every thing aligned. Hope your still under warranty.

    Sent from my SM-G900P using Tapatalk

  6. #6
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    yes I did the change myself... I will add more info soon, but its not hard... its extremelly hard... over 5 hours to disassemble and another 5 hours to make all back...
    I needed 4 days to complete the job.

    Basically is:
    1) farings removed
    2) handlebar removed
    3) tank removed
    4) airbox opened, removed
    5) ecu removed
    6) cam chain tensioner removed
    7) crash guard removed
    8) belli pan removed
    9) water radiator removed
    10) valve head removed
    11) clutch cover removed
    12) water pump removed
    13) side case cover removed
    14) clutch discks removed
    15) clutch basket removed
    16) primary gear nut removed
    17) cam chain guides removed
    18) intermediary gear (the problem finally) remvoed with the chain

    and then all 18 steps back....

    bike is Caponord 1200 Rally 2015 sold as 2016 year (the grayed-gold color)

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  8. #8
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    posted the procedure but looks admin blocked it...

  9. #9
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    Quote Originally Posted by aleib View Post
    posted the procedure but looks admin blocked it...
    I would very much doubt that in here

  10. #10
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    i saw the message "this post must be athorized by administrator" or something like

  11. #11
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    1) remove side firings
    2) remove top tank firing
    3) loose handle bar
    4) remove tank
    5) remove crash bar
    6) remove lower firings and belli pan
    7) remove radiator
    8) remove valve cover
    9) remove airbox
    10) remove ecu
    11) remove cam chain tensioner
    12) remove water pump
    13) remove right side engine cover
    14) remove clutch cover
    15) remove clutch plates
    16) remove clutch basket
    17) remove primary gear
    18) remove cam chain guides
    19) at this point you can remove the intermediary gear with the chain.
    replace it with a new one (all the kit, gear, axle, washer and oring)
    and do all 19 steps back

  12. #12
    apriliaforum prov-nov
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    Like you said... not a DIY job ... not for me at least...
    2015 Caponord White TP
    Heated grips, Gel seat, Givi Screen, Aprilia Top Box, GPR Exhaust, ESE Healtech, RAM Phone mount

  13. #13
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    another two threads with the same...

    http://www.apriliagarage.it/forum/vi...?f=146&t=62256


    https://lnx.caponordforum.com/forum/....php?f=7&t=669


    I will change the back cylinder too soon, based on the degradation of the fron cylinder I assume it will have a 1mm play in about 3/4k kms... so in the next oil/air filter change I will take the opportunity.

    I hope is easier than the fron cylinder!

  14. #14
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    In the US this was recalled. I had both cylinders done about 4 months ago.

  15. #15
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    Hey Bosnz

    Do you have any info on the recall on this issue? I'm close to pulling the trigger on a Rally and wanted to ask the dealer about the recall
    Thanks!

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