Motorcycle engine repair Aprilia SL750 (Shiver, 2007-2016)

Engine removal — vehicle preparation
Remove the air filter case. Remove the coolant radiator. Remove the exhaust system. Place the optional under-sump and rear wheel service stands. Undo and remove the screw and move the coil. Disconnect the engine temperature sensor connector....

Removing the engine from the vehicle
Carry out the operations described under Vehicle preparation . Support the engine by means of belt and hoist. Working on the left side, unscrew and remove the three nuts. Working on the right side, slightly slide off the three bolts. Collect the...

Installing the engine to the vehicle
Place the engine on a suitable lower stand. Lift the engine. Place the engine so that the rear attachments on the chassis are aligned. Working on the right side, insert the three bolts with their washers. Working on the right side, place the spacers...

Removing the starter motor
Disconnect the starter motor power supply cable. Undo and remove the four screws and remove the starter motor.

Removing the flywheel cover
Remove the flywheel cover inspection cap. Unscrew and remove the ten screws (1-2). Note. Screw (2) on the flywheel cover is shorter than screws (1). Remove the flywheel cover using the specific tool. Specific tooling: 020712Y Handle for Flywheel...

Removing the flywheel cover components
Remove the two pick-up fixing screws. Remove the three stator fixing screws. Caution! The pick-up and stator shall be removed simultaneously as they are part of the same electrical branch. See also specifications for this operation.

Magneto flywheel removal
Remove the flywheel cover. Undo and remove the screw and remove the retention plate. Heat the magneto flywheel with the specific heater. Lock the flywheel using the specific tool and loosen the screw. Specific tooling: 020713Y Flywheel extractor...

Freewheel — removal and installation
Removal Heat the magneto flywheel with the specific heater. Undo and remove the six screws. Remove the freewheel from the magneto flywheel. Installation Insert the woodruff key on the crankshaft. Insert the start-up transmission gear after applying...

Water pump removal
Remove the water pump cover. Undo and remove the eleven screws working in a diagonal sequence. Collect the gasket. See also specifications for this operation.

Removing the head cover
The operations described below are valid for both heads. Undo and remove the four screws and collect the rubber rings. Remove the head cover. See also specifications for this operation.

Removing the cylinder head
Note. The operations described below refer to removing only one head but apply to both heads. Remove the head cylinder unit. Undo and remove the screw on the inlet side. Undo and remove the screws on the outlet side. Separate the cylinder from the...

Removing the overhead camshaft
Remove the clutch side crankcase half. Rotate the crankshaft until the rear cylinder reaches the TDC. First remove the rear head cover in order to remove the rear head camshafts. First remove the front head cover in order to remove the front head...

Removing the valves
When removing the valve, mark the components according to the position and the cylinder they belong to, in order to refit the components to their correct positions. Remove the bowl tappets and the adjustment shims using a magnet. Compress the valve...

Checking the overhead camshaft
Check that the camshaft toothed wheel works properly: if it is damaged or does not move smoothly, replace both the timing chain and the camshaft toothed wheel. Camshaft lobes Check that they do not show blue colouring, pitting or scratches;...

Valve and springs check
Caution! Replace the valves one at a time. Do not mix the components. each valve must be inserted into its seat, which is marked prior to removal. Caution! The seat (1) on the valve head cannot be reground. if required, replace the valve. Grinding...

Checking the cylinder head
Using a round scraper, clean off any carbon deposits in the combustion chamber. Caution! Do not use a pointed instrument to avoid damaging or scratching the spark plug threads or the valve seats. Check the head for damage or scratches and replace it...

Removing the chain tensioner
Undo and remove the screw and collect the washer and the internal spring. Unscrew and remove the two screws. Remove the chain tensioner and collect the gasket. See also specifications for this operation.

Timing chain removal
Remove the chain tensioner. Remove the main pinion. Remove the movable chain slider and release the fixed chain slider from the clamp. Unscrew and remove the pin of the timing chain intermediate gear paying attention not to damage the O-ring....

Removing the chain sliders
Remove the chain tensioner and the camshafts from the corresponding head. Front head First remove the clutch cover in order to remove the chain sliders from the front head. Undo and remove the movable chain tensioner slider screw. Slide it off from...

Checking the timing chain
Check the timing chain for damage or stiffness while moving. If required, replace both the timing chain and the camshaft sprocket wheels. Check the timing chain guide for damage. If necessary, replace the parts.

Installing the chain tensioner
Refit the removed timing system chain tensioner on the cylinder - head: Fit the timing chain on the crankshaft and on the intermediate gear. Remove the screw and collect the washer and the spring. Fit the chain tensioner body on the cylinder and...

Timing chain installation
Rotate the crankshaft until the front cylinder piston reaches the top dead centre. Lock the crankshaft with the specific special tool Specific tooling: 020720Y Timing tool If necessary, remove the timing system gears from the camshafts: Place the...

Removing the cylinder
Remove the timing chain. Undo and remove the two head fastener screws located in the timing chain compartment. Undo and remove the outer screw. Undo and remove the four nuts, proceeding in stages and in a diagonal pattern. Ease the cylinder head...

Disassembling the piston
Remove the head and cylinder. Take out the pin locking ring. Lock the connecting rod using the specific tool. Slide off the pin and remove the piston. Specific tooling: 020716Y Connecting rod locking Lock the connecting rod using circlips. Caution!...

Checking the cylinder
All seal surfaces must be clean and flat. Make sure all threads are in proper conditions. Check cylinder sliding surface for signs of friction and scratches. Also check the seal surfaces for damages. Caution! If the grooves on the cylinder liner are...

Checking the piston
Measure the piston skirt diameter "P" with a micrometer (a=10 mm (0.39 in) from the piston lower border). Calculate the clearance between piston and cylinder as follows: Piston - cylinder clearance C = C - P Piston - cylinder clearance: 0.050 -...

Fitting the piston
An arrow stamped on the piston crown indicates the exhaust side. When refitting the piston rings on the piston, the arrow stamped inside the piston must be turned towards the operator. The piston rings are different and must be installed with the...

Installing the cylinder
Fit the stud bolts, if previously removed. Caution! The stud bolts should be fitted so that they protrude. Distribute Loctite 270 (high-strength) on the thread and screw the stud bolt on the crankcase until they protrude by 137 mm (5.39 in), then...

Selecting the base gasket
Place the specific special tool on the piston, which should have sealing rings and be fitted on the connecting rod. Lock the special tool with the clamp. Specific tooling: AP8140302 tool for sealing ring fitting Temporarily, fit the piston to the...

Installing the cylinder head
Place the fixed chain tensioner slider on the cylinder timing chain compartment, opposite to the chain tensioner. Fit a new gasket between the cylinder and the head. Couple the cylinder and the head. Screw without tightening the two screws on the...

Installing the head cover
Caution! Before refitting head covers, clean head and cover surfaces carefully. Apply THREEBOND on the head cover perimeter along the gasket housing. Apply THREEBOND on the head in the areas indicated in the figure. For the remaining operations,...

Splitting the crankcase halves
Fit the special tool, tightly fastening the four screws securing the tool onto the crankcase. Use the special tool to undo and remove the crankshaft fastener nut, retrieving the washer. Specific tooling: 020711Y Engine pinion locking Use a...

Removing the crankshaft
Remove the crankshaft. See also specifications for this operation.

Inspecting the crankcase halves
Bearings and oil seal check Thoroughly clean the two sections of the crankcase, the ball bearings, the threads of the crankcase fixing screws and the bearing seats with a non-aggressive solvent. Clean the seal surfaces and check that they are not...

Inspecting the crankshaft components
Crankshaft axial clearance check The shaft axial clearance on the crankcase should be checked with a comparator mounted on the specific comparator support. The clearance should be between 0.1-0.4 mm (0.0039-0.0157 in). If the clearance is beyond...

Crankcase — removal and installation
Removal Mark the position of the original semi-bushings on the crankcase. To reduce the installation force necessary, score an incision approximately 0.5 mm (0.02 in) deep (without cutting into the steel shell) in each semi-bushing in the area...

Installing the crankshaft
Place the left side crankcase half on the engine support adequately. Place the crankshaft on the seat of the crankcase half with caution. See also specifications for this operation.

Refitting the crankcase halves
Fit the strum box, if previously removed. Tighten the two strum box fixing screws. Turn the engine support into horizontal position. Place the left crankcase half on the engine support, fitting it on the engine support pins. Caution! Take particular...