Aprilia Rotax Engine Type 120 154 177 2001 Workshop Service Repair Manual
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DESCRIPTION:
“This Workshop Manual contains information, data, and procedures necessary for servicing and repair of the ROTAX type 120/154/177 engines. It is intended for use by professional mechanics who have been properly trained in the maintenance of these engines, and who have available all of the common and special tools which are required for this work. If any procedure data or information in this manual is unclear to you, contact Aprilia Service at the address or phone number given below.”
- The information in this Workshop Manual is current as of the date of publication. Since BOMBARDIER-ROTAX and Aprilia constantly strive to improve their scooter motors and scooters, changes are being continuously introduced as engines are produced.
- Therefore, some of the information in this manual may not be applicable to the scooter which you are servicing. To make sure that you always have the latest BOMBARDIERROTAX and Aprilia information, contact Aprilia Service.
- While this book has been carefully compiled by the engineering and service departments of BOMBARDIERROTAX and Aprilia, we cannot guarantee the accuracy or applicability of the material in this manual. We will deeply appreciate your pointing out any errors to the address given below.
- BOMBARDIER-ROTAX and Aprilia reserve the right to change the information in this manual at any time, without notice to anyone. The reprinting, traslation, or copying of this manual, either partially or completely, is strictly prohibited, unless authorized in writing by Aprilia.
TABLE OF CONTENTS:
Aprilia Rotax Engine Type 120 154 177 2001 Workshop Service Repair Manual
Foreword 2
Important information
Recurrent symbols 6
General precautions and safety rules 6
Parts – list 9
Engine serial number – position 9
Technical data type 120 Leonardo and 120 Scarabeo 10
Technical data type 154 Leonardo and 154 Scarabeo 12
Technical data type 177 Scarabeo 14
Engine servicing schedule 16
Servicing and repair requirements 16
General notes on servicing and repair procedures 18
Fault finding 20
Service tools, equipment, sealing and lubricating agents 27
Standard tools 30
Measuring instruments 30
Fasteners 30
Sealing and lubricating agents 31
Torque wrench settings34
Oil circuit 39
Repairs without removing engine 40
Removing engine from frame 41
Positioning engine on stand 42
Dismantling the engine
Starter motor — remove 43
Variator cover— remove 43
Carburetor hose and valve cover — remove 44
Locking crankshaft at top dead center 45
Timing chain — check 47
Chain tensioner and timing gear — remove 47
Cylinder head — remove 48
Chain guide and chain tension guide — remove 49
Cylinder — remove 49
Piston — remove 50
Oil filter and oil pressure switch — remove 51
Ignition and electric starter gearing — remove 51
Oil pump — remove 53
Water pump — remove53
Chain tension guide and timing chain — remove 55
Oil strainer — remove 55
Variator — remove 56
Oil pressure valve 58
Transmission — remove 58
Half crankcase — separate 61
Crankshaft — remove 62
Servicing procedures
Crankcase63
Half crankcase, flywheel side (MS) — flywheel side servicing 65
Half crankcase, clutch side — removal and refitting of plain bearings,
ball bearings, oil seal, etc 69
Transmission cover — servicing 76
Crankshaft 80
Transmission 82
Variator, primary drive side — check 83
Secondary drive 87
Timing gear 91
Chain guide and chain tension guide 92
Oil pump and water pump gearing 92
Oil pressure retaining valve 94
Cylinde 95
Piston and piston pin 95
Piston rings 97
Cylinder head 99
Valves 102
Valve seats 103
Rocker arms 105
Thermostat — check (Leonardo 120 only) 107
Valve cover 108
Ignition 109
Ignition cover 112
Spark plug 113
Electric starter gearing 114
Idle gear 115
Starter motor 115
Reassembling the engine
Half crankcase, flywheel side 116
Half crankcase, clutch side 117
Oil strainer and magnetic drain plug — refit 123
Piston — refit 124
Cylinder — refit 125
Chain guide and chain tension guide — refit 127
Cylinder head — refit 127
Chain tensioner — refit 128
Valve clearance — adjust 129
Oil filter — refit 130
Flywheel side components — refit 130
Water pump, idle gear and ignition cover — refit 131
Carburetor hose — refit 134
Starter motor — install 134
Variator cover — refit 134
Refitting engine onto frame 135
Filling 135
Engine test 137
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LANGUAGE:ITALIAN & ENGLISH
PAGES:140
DOWNLOADABLE:YES
FILE TYPE:PDF
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