APRILIA C361M Workshop Manual
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APRILIA C361M Workshop Manual

APRILIA C361M Workshop Manual

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Engines C361M /C364M / C216M
00/2004-10
workshopmanual

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Summary of Contents for APRILIA C361M

  • Page 1 1234 4 Engines C361M /C364M / C216M 00/2004-10 workshopmanual...
  • Page 2 INTRODUCTION ENGINES C361M / C364M INTRODUCTION GENERAL INFORMATION TECHNICAL INFORMATION ENGINE UPDATES ENGINE C364M UPDATES ENGINE C216M 0 - 1...
  • Page 3 INTRODUCTION ENGINES C361M / C364M SUMMARY 0.1. INTRODUCTION ..........................3 0.1.1. INTRODUCTION ........................3 0.1.2. REFERENCE MANUALS ......................4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..............5 0 - 2...
  • Page 4 MENT; we will be pleased to provide all necessary information and assistance as well as keeping you updated on changes and modifications to the vehicle. aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual.
  • Page 5 INTRODUCTION ENGINES C361M / C364M 0.1.2. REFERENCE MANUALS ENGINE WORKSHOP MANUALS aprilia part# (description) 8140731 8140732 8140733 8140734 8140735 8140736 SPECIAL TOOLS MANUALS aprilia part# (description) H001 0 - 4...
  • Page 6 INTRODUCTION ENGINES C361M / C364M 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F...
  • Page 7 INTRODUCTION ENGINES C361M / C364M RIGHT SIDE = right side = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. =hexagonal head = flat head screw = Twin Spark Ignition...
  • Page 8 GENERAL INFORMATION ENGINES C361M / C364M GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION ENGINES C361M / C364M SUMMARY 1.1. STRUCTURE OF THE MANUAL ..................... 3 1.1.1. CONVENTIONS USED IN THE MANUAL ................3 1.1.2. SAFETY WARNINGS ......................4 1.2. GENERAL RULES ........................... 5 1.2.1. BASIC SAFETY RULES ......................5 1.3. DANGEROUS ELEMENTS......................7 1.3.1.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION ENGINES C361M / C364M 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual.

  • Page 11: Safety Warnings

    INFORMAZIONI GENERALI RSV mille M.Y. 2004 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.

  • Page 12: General Rules

    GENERAL INFORMATION ENGINES C361M / C364M 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES USED GEARBOX AND FORK OILS DANGER In case any maintenance operation should be required, it is advisable to use latex gloves. Gear oil may cause serious damage to the skin if handled daily and for long periods.
  • Page 13 Never clean a bearing with compressed air. NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 14: Dangerous Elements

    GENERAL INFORMATION ENGINES C361M / C364M engine 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS LUBRICANTS DANGER A good lubrication ensures the vehicle safety. Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean type of lubricant can lead to the engine or gearbox seizure, thus leading to serious accidents, perso- nal injury or even death.

  • Page 15: Running-In

    GENERAL INFORMATION ENGINES C361M / C364M 1.4. RUNNING-IN 1.4.1. RUNNING-IN RECOMMENDATIONS The running-in of the engine is primary to ensure its correct functioning and long life. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes un- dergo a more effective running-in.

  • Page 16: Identification Data

    GENERAL INFORMATION ENGINES C361M / C364M 1.5. IDENTIFICATION DATA 1.5.1. ENGINE NUMBER • The engine number (1) is stamped on the rear side of the engine. NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In particular, the alteration of the frame number results in the immediate invalidity of the warranty.
  • Page 17 TECHNICAL INFORMATION ENGINES C361M / C364M TECHNICAL INFORMATION 2 - 1...
  • Page 18 TECHNICAL INFORMATION ENGINES C361M / C364M SUMMARY 2.1. GENERAL TECHNICAL INFORMATION ..................3 2.1.1. TECHNICAL DATA........................3 2.1.2. TABLE OF LUBRICANTS......................4 2.1.3. TIGHTENING TORQUE SETTINGS ..................5 2.1.4. SPECIAL TOOLS ........................6 2 - 2...

  • Page 19: General Technical Information

    TECHNICAL INFORMATION ENGINES C361M 2.1. GENERAL TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA ENGINE Model C361M Type 2 temps Number of cylinders Single-cylinder, horizontal Total displacement 49,38 cm Bore / stroke 40 mm / 39,3 mm Compression ratio 12,4 ± 0,5 : 1...

  • Page 20: Table Of Lubricants

    INFORMAZIONI TECNICHE GENERALI RSV mille M.Y. 2004 2.1.2. TABLE OF LUBRICANTS LUBRIFICANT PRODUCT recommended: F.C., SAE 75W - 90 As an alternative to the recommended oil, it is possible to use high-quality Transmission oil oils with characteristics in compliance with or superior to the A.P.I. GL-4 specifications.

  • Page 21: Tightening Torque Settings

    GENERAL TECHNICAL INFORMATION ENGINE C361M / C364M 2.1.3. TIGHTENING TORQUE SETTINGS NAME ENGINE TRANSMISSION COVER TRANSMISSION COVER BOLT 12 ÷ 13 DRIVING PULLEY DRIVING PULLEY NUT 40 ÷ 44 CLUTCH CASE NUT 40 ÷ 44 CLUTCH CLUTCH NUT 55 ÷ 60...

  • Page 22: Special Tools

    ATTREZZATURA SPECIFICA MOTORE 125 - 200 2.1.4. SPECIAL TOOLS In order to perform assembly, reassembly and settings correctly, spe- cial tools suitable for the task must be used. The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised methods.
  • Page 23 ENGINE ENGINES C361M / C364M ENGINE 3 - 1...
  • Page 24 ENGINE ENGINES C361M / C364M SUMMARY ........................4 3.1. TRANSMISSION COVER 3.1.1. REMOVAL OF TRANSMISSION COVER................4 3.1.2. REPLACEMENT OF TRANSMISSION COVER ..............5 3.1.3. TIGHTENING TORQUE SETTINGS ..................6 3.2. DRIVING PULLEY..........................7 3.2.1. REMOVAL OF DRIVING PULLEY ..................7 3.2.2.
  • Page 25 ENGINE ENGINES C361M / C364M 3.12.2. REPLACEMENT OF THE FLYWHEEL..................68 3.12.3. TIGHTENING TORQUE SETTINGS..................69 3.13. FUEL FEED SYSTEM........................70 3.13.1. DISASSEMBLY OF THE CARBURETTOR BODY ..............70 3.13.2. REPLACEMENT OF THE CARBURETTOR BODY ..............72 3.13.3. CHECKING THE FUEL FEED SYSTEM................74 3.13.4. TIGHTENING TORQUE SETTINGS..................75 3.14.

  • Page 26: Transmission Cover

    ENGINE ENGINE C361M 3.1. TRANSMISSION COVER 3.1.1. REMOVAL OF TRANSMISSION COVER • Take out the mounting bolts and ease off the cover by means of light taps with a mallet. 3 - 4...

  • Page 27: Replacement Of Transmission Cover

    ENGINE ENGINE C361M 3.1.2. REPLACEMENT OF TRANSMISSION COVER • Position the transmission cover and tighten the mount- ing bolts. 3 - 5...

  • Page 28: Tightening Torque Settings

    ENGINE ENGINE C361M 3.1.3. TIGHTENING TORQUE SETTINGS NAME TRANSMISSION COVER TRANSMISSION COVER BOLT 12 ÷ 13 3 - 6...

  • Page 29: Driving Pulley

    ENGINE ENGINES C361M / C364M 3.2. DRIVING PULLEY 3.2.1. REMOVAL OF DRIVING PULLEY • Hold the pulley firm with the specific tool. • Unscrew the central nut plus washer, remove the drive take-off and the plastic fan. • Remove the fixed half-pulley.
  • Page 30 ENGINE ENGINES C361M / C364M • Remove the starter motor pinion. • Remove the rollers lock plate and guide shoes. Take off the rollers. 3 - 8...

  • Page 31: Replacement Of Driving Pulley

    ENGINE ENGINES C361M / C364M 3.2.2. REPLACEMENT OF DRIVING PULLEY • Pre-assemble the moving half-pulley and rollers lock plate. • Position the assembly complete with bush on the drive shaft. • Remount the stop washer, insert the starter motor pin- ion in its seat and position the transmission belt.
  • Page 32 ENGINE ENGINES C361M / C364M • Prevent the pulley from turning with the specific tool and tighten the lock nut to the correct torque value with a torque spanner. N.B. Use a new nut every time the pulley is remounted.

  • Page 33: Driving Pulley Check

    ENGINE ENGINES C361M / C364M 3.2.3. DRIVING PULLEY CHECK • Check the inside bearing for abnormal wear and measure its diameter. Do not lubricate or clean the bearing. • Minimum permitted diameter: 20.12 mm • Standard diameter: 20.021 mm •...

  • Page 34: Tightening Torque Settings

    MOTORE ENGINE C361M 3.2.4. TIGHTENING TORQUE SETTINGS NAME DRIVING PULLEY DRIVING PULLEY NUT 40 ÷ 44 CLUTCH CASE NUT 40 ÷ 44 3 - 12...

  • Page 35: Driven Pulley

    ENGINE ENGINES C361M / C364M 3.3. DRIVEN PULLEY 3.3.1. REMOVAL OF DRIVEN PULLEY - CLUTCH • Hold the clutch cover firm with the specific tool. • Remove the nut and clutch cover. • Slip the complete driven pulley - clutch assembly off the driving belt.

  • Page 36: Dismantling The Driven Pulley

    ENGINE ENGINES C361M / C364M 3.3.2. DISMANTLING THE DRIVEN PULLEY • Use the specific tools to slip off the pulley pins retainng collar. • Remove the three retaining pins. • Separate the moving from the fixed half-pulley. • Remove the two outer O-rings and the two inner seal- ing rings of the moving half-pulley.
  • Page 37 ENGINE ENGINES C361M / C364M • Remove the roller bearing with a mallet and an appro- priately sized punch. Support the half-pulley suitably to prevent deformation of its driving belt running surface. • Remove the ball bearing snap ring. •...

  • Page 38: Recomposition Of The Driven Pulley

    ENGINE ENGINES C361M / C364M 3.3.3. RECOMPOSITION OF THE DRIVEN PULLEY • Use the specific tooling to mount a new ball bearing on the fixed driven half-pulley. • Insert the ball bearing snap rings. • Mount the roller bearing with its outside writing visible.
  • Page 39 ENGINE ENGINES C361M / C364M • Carefully lubricate the moving driven half-pulley. • Fit the half-pulley on the bush. Make sure no damage is done to the oil shields. • Remount the three retaining pins. • Reinsert the collar. 3 - 17...

  • Page 40: Replacement Of The Driven Pulley - Clutch

    ENGINE ENGINES C361M / C364M 3.3.4. REPLACEMENT OF THE DRIVEN PULLEY - CLUTCH • Bring the moving driven half-pulley up to the clutch and set it at the correct distance by hand. Insert the driving belt in the right assembly direction.

  • Page 41: Clutch On The Bench

    ENGINE ENGINES C361M / C364M 3.4. ON THE BENCH CLUTCH 3.4.1. SEPARATION CLUTH - DRIVING PULLEY • Use the specific tool to position the clutch - moving pul- ley assembly. • Apply force to the central bolt. Do not overtighten it as this could damage the tool.

  • Page 42: Clutch - Driven Pulley Check

    ENGINE ENGINES C361M / C364M 3.4.2. CLUTCH - DRIVEN PULLEY CHECK • Measure the outside diameter of the fixed driven half- pulley bush. • Minimum permitted diameter: 33.96 mm • Standard diameter: 33,965 -33.985 mm • Measure the inside diameter of the fixed driven half- pulley bush.
  • Page 43 ENGINE ENGINES C361M / C364M • Measure the inside diameter of the clutch cover and checl its state of wear. + 0,2 • Standard value 107 • Max. value 0,20 mm 3 - 21...

  • Page 44: Assembly Of The Clutch Driven Pulley Unit

    ENGINE ENGINES C361M / C364M 3.4.3. ASSEMBLY OF THE CLUTCH DRIVEN PULLEY UNIT • Pre-assemble the pulley unit with the pressure spring, sheath and centrifugal clutch. • Place the components in the tool and load the spring. Make sure no damage is caused to the plastic sheath and the threaded end of the tang.

  • Page 45: Tightening Torque Settings

    ENGINE ENGINE C361M 3.4.4. TIGHTENING TORQUE SETTINGS NAME CLUTCH CLUTCH NUT 55 ÷ 60 3 - 23...

  • Page 46: Head Cover - Injection Assembly

    ENGINE ENGINE C361M 3.5. HEAD COVER - INJECTION ASSEMBLY 3.5.1. REMOVAL OF HEAD COVER INJECTION AS- SEMBLY • Unscrew the bolt attaching the air delivery pipe to the injection head and remove the pipe. • Unscrew the head attachment bolts and remove the assembly, including the petrol injector and pressure regulator.
  • Page 47 ENGINE ENGINE C361M • Unscrew and remove the coolant outlet union with its 0-ring from the head. • Disconnect the pipe holding clamp and remove the in- side recirculation duct. • Undo the four bolts and remove the head cover along with its gasket.

  • Page 48: Rimontaggio Testa - Gruppo Iniezione

    ENGINE ENGINE C361M 3.5.2. RIMONTAGGIO TESTA - GRUPPO INIEZIONE • Clean the head thoroughly and check the soundness of its mating surface. • Make sure the ring seals are not damaged and replace if necessary. • Position the head and cross-tighten its nuts to the cor- rect torque value.
  • Page 49 ENGINE ENGINE C361M • Replace the coolant outlet union with its 0-ring and tighten its bolts to the correct torque value. • Remount the inside recirculation duct and replace the clamp. • Replace the injector assembly and tighten its bolts to the correct torque value.

  • Page 50: Changing The Injector Ring Seal

    ENGINE ENGINE C361M 3.5.3. CHANGING THE INJECTOR RING SEAL • Remove the feed assembly. • The injector ring seal must be broken to remove it. • Make sure the ring seals are not worn and replace if necessary. • Clean the air injector and its seat thoroughly and re- move any carbon residues.
  • Page 51 ENGINE ENGINE C361M • Use the specific tool to tighten the ring seal in its seat. • Replace the injector on the head quickly to make sure the seal does not dilate again. 3 - 29...

  • Page 52: Tightening Torque Settings

    MOTORE ENGINE C361M 3.5.4. TIGHTENING TORQUE SETTINGS NAME ENGINE HEAD ENGINE HEAD BOLT 10 ÷ 11 COOLANT OUTLET UNION ATTACHMENT BOLT 3 ÷ 4 TEMPERATURE SENSOR 18 ÷ 22 PLUG ATTACHMENT 11 ÷ 14 ATTACHMENT BOLT INJECTION HEAD 3 ÷ 4...

  • Page 53: Cylinder And Piston

    ENGINE ENGINES C361M / C364M 3.6. CYLINDER AND PISTON 3.6.1. REMOVAL OF THE CYLINDER AND PISTON • Remove the cylinder with its gasket. Support the piston to make sure it is not damaged. • Protect the cylinder seat and then use the specific tool to remove the two pin retainers from the cavities in the piston.
  • Page 54 ENGINE ENGINES C361M / C364M • Remove the piston circlips. Make sure they do not get damaged when reassembled. N.B. Make a note of the position of the segments so that they are not inverted when reassembled. 3 - 32...

  • Page 55: Replacement Of The Cylinder And Piston

    ENGINE ENGINES C361M / C364M 3.6.2. REPLACEMENT OF THE CYLINDER AND PIS- • Insert the circlips on the piston. Make sure their notches are in the right position. • Insert the roller lane in the foot of the con rod.
  • Page 56 ENGINE ENGINES C361M / C364M • Use a punch to position the pin retaining ring. • Mount the ring with the peg. • Fit a new gasket. Lubricate the cylinder and replace it. 3 - 34...

  • Page 57: Checking The Cylinder And Piston

    ENGINE ENGINES C361M / C364M 3.6.3. CHECKING THE CYLINDER AND PISTON • Make sure the roller lane of the small end of the con rod is not abnormally worn. • Measure the inside diameter of the small end with a bore gauge.

  • Page 58: Cylinder/Piston Mating Categories

    ENGINE ENGINES C361M / C364M 3.6.4. CYLINDER/PISTON MATING CATEGORIES MATING CATEGORIES ASSEMBLY PART SIZE PLAY "A" SYMBOL CYLINDER "E" PISTON "C" 39,990÷39,997 39,943÷39,950 Ø 40 -0,01 Cylinder +0,018 39,997÷40,004 39,950÷39,957 40,004÷40,011 39,957÷39,964 Ø 40 -0,02 Piston -0,057 40,011÷40,018 39,964÷39,971 40,19÷40,197 40,143 ÷...

  • Page 59: Selection Of The Cylinder Gasket

    ENGINE ENGINES C361M / C364M 3.6.5. SELECTION OF THE CYLINDER GASKET • Lubricate the cylinder and fit it temporarily on the piston without a gasket. • Fit the comparator on the specific tool, zero it on a ref- erence surface and mount the assembly on the cylin- der without altering the position of the comparator.

  • Page 60: Starter Motor

    ENGINE ENGINES C361M /C364M 3.7. STARTER MOTOR 3.7.1. DISASSEMBLY • Remove the attachment bolts and take off the motor. • Use an appropriate tool to remove the ring seal. 3.7.2. REPLACEMENT • Insert the gasket. • Position the motor and tighten its attachment bolts.

  • Page 61: Mixer

    ENGINE ENGINES C361M / C364M 3.8. MIXER 3.8.1. DISASSEMBLY • Take off the clamp and disonnect the pipe from the pump housing oil inlet union. • Undo the bolts and extract the mixer with the housing pipes gasket. 3 - 39...

  • Page 62: Replacement Mixer

    ENGINE ENGINES C361M / C364M 3.8.2. REPLACEMENT MIXER • Replace the pump housing oil inlet union. • Insert the pipes gasket in the housing. • Position the mixer and tighten its bolts. • It is advisable to bleed the reassembled mixer through the central bolt.

  • Page 63: Coolant Pump

    ENGINE ENGINES C361M / C364M 3.9. COOLANT PUMP 3.9.1. DISASSEMBLY COOLANT PUMP • Position the specific thread retaining tool. Be careful not to overload the plastic impeller during the locking stages. • Remove the drive belt together with the two toothed crown wheels.
  • Page 64 ENGINE ENGINE C361M /C364M • Use ths specific tool to unscrew the shaft by turning the spanner clockwise (left-hand thread). Take out the shaft with the appropriate tool. • Use an appropriate tool to remove the pump shaft seat ring seal.

  • Page 65: Replacement Coolant Pump

    ENGINE ENGINES C361M / C364M 3.9.2. REPLACEMENT COOLANT PUMP • Check the shaft for abnormal wear and bearing noise. If necessary, change the shaft and the bearings. • Clean the housings. • Position the new, lubricated oil seal on the specific tool and bring it into contact with the specific tool.
  • Page 66 ENGINE ENGINES C361M / C364M • Remount the shaft and bearings by pushing and at the same time turning the spanner anticlockwise. Be care- ful not to damage the thread of the bronze insert or separate the insert of the plastic impeller.

  • Page 67: 3.10. Rear Hub

    ENGINE ENGINES C361M / C364M 3.10. REAR HUB 3.10.1. DISASSEMBLY OF REAR HUB AND WHEEL BEARING • Drain the oil from the hub and remove the mounting bolts. • Remove the hub cover complete with the driven pulley shaft by means of light taps with a mallet.
  • Page 68 ENGINE ENGINES C361M / C364M • Remove the oil seal and circlip. • Remove the bearing by driving it in from the outside with an appropriate punch. 3 - 46...

  • Page 69: Disassembly Of Driven Pulley Shaft

    ENGINE ENGINES C361M / C364M 3.10.2. DISASSEMBLY OF DRIVEN PULLEY SHAFT • Remove the circlip from inside the cover. • Position the specific pipe on the inner race of the bear- ing and on the side of the pulley shaft toothing. Use a press to force out the driven pulley shaft.

  • Page 70: Checking The Wheel Shaft

    ENGINE ENGINES C361M / C364M 3.10.3. CHECKING THE WHEEL SHAFT • Make sure that the three shafts are free from wear or deformation on the toothed surfaces and the bearing and oil shield contacts. • Make sure the mating surfaces are free from abnor- malities and deformation.

  • Page 71: Replacement Of The Driven Pulley Shaft

    ENGINE ENGINES C361M / C364M 3.10.4. REPLACEMENT OF THE DRIVEN PULLEY SHAFT • Heat the hub cover and use the specific tool to insert a new bearing with its screen facing the oil shield. • Mount the circlip with its concave or radiate part on the bearing side.

  • Page 72: Eplacement Of Rear Hub And Wheel Bearing

    ENGINE ENGINES C361M / C364M 3.10.5. EPLACEMENT OF REAR HUB AND WHEEL BEARING • Use a heat gun to heat the half-casing on the transmis- sion side. • Lubricate the outer plate. Use a mallet to insert the bearing with the special adapter.
  • Page 73 ENGINE ENGINE C361M 3.10.6. TIGHTENING TORQUE SETTINGS NAME REAR HUB HUB COVER BOLT 11 ÷ 13 3 - 51...

  • Page 74: 3.11. Crankcase

    ENGINE ENGINES C361M / C364M 3.11. CRANKCASE 3.11.1. SEPARATION OF CASE AND DRIVE SHAFT • Remove the attachment bolts of the half-case on the flywheel side. • Place the guard on the drive shaft and correctly centre the specific tool for removal of the half-case on the fly- wheel side.
  • Page 75 ENGINE ENGINES C361M / C364M • Install the specific tool with its guard on the half-case on the transmission side. • Use the hex spanner to separate the drive shaft from the half-case on the transmission side. 3 - 53...

  • Page 76: Disassembly Of The Drive Shaft Bearings

    ENGINE ENGINES C361M / C364M 3.11.2. DISASSEMBLY OF THE DRIVE SHAFT BEAR- INGS • Mesh the half-rings on the bearings with the respective bolts. • Position the specific tool and tighten the attachment bolts. • Work on the bolt to dismount the bearing.
  • Page 77 ENGINE ENGINES C361M / C364M • Repeat this operation on the second bearing using the tool bolts. 3 - 55...

  • Page 78: Replacement Of The Drive Shaft Bearings

    ENGINE ENGINES C361M / C364M 3.11.3. REPLACEMENT OF THE DRIVE SHAFT BEAR- INGS • Place the bearings in a cold oil bath and heat them to about 150°C. • Set the drive shaft in the special holder. • Insert the bearings alternately. Use the specific tool to ensure their proper abutment.

  • Page 79: Disassembly Of The Crankcase Oil Shields

    ENGINE ENGINES C361M / C364M 3.11.4. DISASSEMBLY OF THE CRANKCASE OIL SHIELDS • Use the specific tool and light taps with a mallet to re- move the oil shield on the flywheel side. • Repeat this operation on the transmission side.

  • Page 80: Replacement Of The Crankcase Oil Shields

    ENGINE ENGINES C361M / C364M 3.11.5. REPLACEMENT OF THE CRANKCASE OIL SHIELDS • Correctly lubricate a new oil shield. Fit it on the fly- wheel side (smaller diameter) solely with the punch of the specific tool to ensure its proper axial alignment.
  • Page 81 ENGINE ENGINES C361M / C364M • Lubricate the bearings and big end. 3 - 59...

  • Page 82: Checking The Halfcase

    ENGINE ENGINES C361M / C364M 3.11.6. CHECKING THE HALFCASE • Clean the mating surfaces. Remove the remains of the Loctite and the paper gasket of the cylinder. • Check the mating surfaces and the contacts of the bearings and oil shields.

  • Page 83: Checking The Drive Shaft

    ENGINE ENGINES C361M / C364M 3.11.7. CHECKING THE DRIVE SHAFT • Check the cam track for wear. Make sure there is no scoring on the axial play surfaces. 3.11.8. DRIVE SHAFT - CON ROD AXIAL PLAY CHECK. PART SIZE PLAY...

  • Page 84: Recomposition Of The Crankcase And Drive Shaft

    ENGINE ENGINES C361M / C364M 3.11.9. RECOMPOSITION OF THE CRANKCASE AND DRIVE SHAFT • Position the half-case on two suitable supports. Use a heat gun to heat the seat of the bearing to about 120°C. • Insert the drive shaft until the bearing reaches its end of travel stops.
  • Page 85 ENGINE ENGINES C361M / C364M • Use a heat gun to heat the half-case on the flywheel side in the same way as on the transmission side. • Mate the surfaces of the flywheel side and transmis- sion side half-cases.

  • Page 86: Checking The Play Of The Bearings

    ENGINE ENGINES C361M / C364M 3.11.10. CHECKING THE PLAY OF THE BEARINGS • Fit the specific magnetic support with comparator on the end of the drive shaft. • Check the axial play of the drive shaft. It should be: 0.10 - 0.12 mm when the case is hot.
  • Page 87 ENGINE ENGINE C361M 3.11.11. TIGHTENING TORQUE SETTINGS NAME ENGINE CASE CASE CLOSING BOLT 12 ÷ 13 3 - 65...

  • Page 88: 3.12. Flywheel

    ENGINE ENGINE C361M 3.12. FLYWHEEL 3.12.1. DISMOUNTING THE FLYWHEEL • Unscrew the bolts and take off the flywheel cover. Pay attention to the connector. Hold the flywheel firm with the specific compass wrench and remove the flywheel attachment hex nut.
  • Page 89 ENGINE ENGINE C361M • Remove the coolant inlet pipe. • Unscrew the attachment bolts and remove the stator complete with the cables and rev sensor. 3 - 67...

  • Page 90: Replacement Of The Flywheel

    ENGINE ENGINE C361M 3.12.2. REPLACEMENT OF THE FLYWHEEL • Insert the stator complete with cables and rev sensor and tighten the bolts to the correct torque value. • Reposition the coolant inlet pipe and rev sensor and tighten their screws.
  • Page 91 ENGINE ENGINE C361M 3.12.3. TIGHTENING TORQUE SETTINGS NAME FLYWHEEL FLYWHEEL NUT 40 ÷ 44 3 - 69...

  • Page 92: 3.13. Fuel Feed System

    ENGINE ENGINE C361M 3.13. FUEL FEED SYSTEM 3.13.1. DISASSEMBLY OF THE CARBURETTOR BODY • Use a Torx spanner to loosen the manifold bolts and remove the carburettor body complete with the induc- tion manifold from the case. • Loosen the clamp bolt and separate the carburettor body from the manifold.
  • Page 93 ENGINE ENGINE C361M • Remove the fins support. 3 - 71...

  • Page 94: Replacement Of The Carburettor Body

    ENGINE ENGINE C361M 3.13.2. REPLACEMENT OF THE CARBURETTOR BODY • Insert the fins support on the case. • Insert the diaphragm and paper gasket with the rims turned towards the fins support. • Mount the carburettor body on the induction manifold.
  • Page 95 ENGINE ENGINE C361M • Replace the manifold complete with the carburettor body and tighten the bolts to the correct torque value. 3 - 73...

  • Page 96: Checking The Fuel Feed System

    ENIGNE ENGINE C361M 3.13.3. CHECKING THE FUEL FEED SYSTEM • Check that the movement of the gas valve does not show abnormal play or slackening. • Make sure the fins support is not worn and that the support surfaces of the petals are not warped.
  • Page 97 ENGINE ENGINE C361M 3.13.4. TIGHTENING TORQUE SETTINGS NAME FUEL SUPPLY SYSTEM THROTTLE BODY MANIFOLD BOLT 7 ÷ 8 AIR COMPRESSOR BOLT 3 ÷ 4 3 - 75...

  • Page 98: Positive Displacement Blower

    ENGINE ENGINE C361M 3.14. POSITIVE BLOWER DISPLACEMENT 3.14.1. DISASSEMBLY OF THE POSITIVE DISPLACE- MENT BLOWER • Remove the manifold. Use an appropriate spanner to remove the air piping union from the injection head. • Unscrew the blower attachment bolts from the housing and take out the blower.

  • Page 99: Replacement Of The Positive Displacement Blower

    ENGINE ENGINE C361M 3.14.2. REPLACEMENT OF THE POSITIVE DIS- PLACEMENT BLOWER • Remove the flywheel cover and set the shaft with the cam at its bottom dead centre point. • Fit the O-ring gasket and insert the blower in the hous- ing.

  • Page 100: Checking The Blower

    ENGINE ENGINE C361M 3.14.3. CHECKING THE BLOWER • Check the contact roller for signs of abnormal wear or overheating. • Use a feeler gauge to measure the axial play of the driver roller. Place its blade between the roller and one of the two shim adjustments.
  • Page 101 UPDATES ENGINE C364M ENGINES C364M UPDATES ENGINE C364M 4 - 1...
  • Page 102 UPDATES ENGINE C364M ENGINES C364M SUMMARY 4.1. GENERAL TECHNICAL INFORMATION ..................3 4.1.1. TECHNICAL DATA........................3 4.2. ENGINE HEAD..........................5 4.2.1. DISMOUNTING THE HEAD ....................5 4.2.2. REPLACEMENT OF THE HEAD .................... 6 4.2.3. TIGHTENING TORQUE SETTINGS ..................7 4.3. FLYWHEEL ............................

  • Page 103: General Technical Information

    UPDATES ENGINE C364M ENGINE C364M 4.1. GENERAL TECHNICAL INFORMATION 4.1.1. TECHNICAL DATA ENGINE Model C364M Type 2 temps Number of cylinders Single-cylinder, horizontal Total displacement 49,38 cm Bore / stroke 40 mm / 39,3 mm Compression ratio 12,1 ± 0,5 : 1 Starting electrical + kick starter Engine idle rpm...
  • Page 104 UPDATES ENGINE C364M ENGINES C364M IGNITION Type C.D.I. Spark advance 20° ± 3° before TDC Resistance 5 KW SPARK PLUG Standard CHAMPION RG6YC Spark plug gap 0,6 – 0,7 mm 4 - 4...

  • Page 105: Engine Head

    UPDATES ENGINE C364M ENGINE C364M 4.2. ENGINE HEAD 4.2.1. DISMOUNTING THE HEAD • Unscrew and take out the plug. • Slacken the clamp and remove the inside recirculation duct. • Unscrew and carefully remove the temperature sensor. • Unscrew the four nuts and take off the head with its two gaskets.

  • Page 106: Replacement Of The Head

    UPDATES ENGINE C364M ENGINE C364M 4.2.2. REPLACEMENT OF THE HEAD • Clean the gasket beds and make sure they are not damaged. • Insert the head with its gaskets and cross-tighten the four bolts to the correct torque value. • Spread sealant over the seat of the temperature sensor and tighten it to the correct torque value.

  • Page 107: Tightening Torque Settings

    UPDATES ENGINE C364M ENGINE C364M 4.2.3. TIGHTENING TORQUE SETTINGS NAME ENGINE HEAD ENGINE HEAD BOLT 10 ÷ 11 COOLANT OUTLET UNION ATTACHMENT BOLT 3 ÷ 4 TEMPERATURE SENSOR 18 ÷ 22 PLUG ATTACHMENT 11 ÷ 14 ATTACHMENT BOLT INJECTION HEAD 3 ÷...

  • Page 108: Flywheel

    UPDATES ENGINE C364M ENGINE C364M 4.3. FLYWHEEL 4.3.1. DISMOUNTING THE FLYWHEEL • Remove the cover, hold the flywheel firm with the spe- cific compass wrench and remove the flywheel attach- ment hex nut. • Insert the specific extractor and work the wrenches to remove the flywheel.
  • Page 109 UPDATES ENGINE C364M ENGINE C364M • Unscrew the attachment bolts and remove the stator complete with the cables and rev sensor. 4 - 9...

  • Page 110: Replacement Of The Flywheel

    UPDATES ENGINE C364M ENGINE C364M 4.3.2. REPLACEMENT OF THE FLYWHEEL • Insert the stator complete with cables and rev sensor and tighten the bolts to the correct torque value. • Reposition the coolant inlet pipe and rev sensor and tighten their screws. •...

  • Page 111: Sector Gear

    UPDATES ENGINE C364M ENGINE C364M 4.4. SECTOR GEAR 4.4.1. DISASSEMBLY OF THE SECTOR GEAR AND PINION • Remove the pedal starter pinion. • Remove the pedal starter lever, then remove the circlip and ring seal. Ease off the sector gear and spring with a mallet.

  • Page 112: Replacement Of The Sector Gear

    UPDATES ENGINE C364M ENGINE C364M 4.4.2. REPLACEMENT OF THE SECTOR GEAR • Lubricate and load the spring with the specific tool, then replace the sector gear. • Replace the pedal starter return pinion. • Insert the ring seal and circlip. •...

  • Page 113: Air Cleaner

    UPDATES ENGINE C364M ENGINE C364M 4.5. AIR CLEANER 4.5.1. REMOVAL OF AIR CLEANER BOX • Loosen the air cleaner manifold clamp screw. • Take out the attachment bolts. • Cut the outside air intake sleeve clamp. • Separate the air cleaner box from the carburettor bidy and intake sleeve.

  • Page 114: Removal Of Air Cleaner

    UPDATES ENGINE C364M ENGINE C364M 4.5.2. REMOVAL OF AIR CLEANER • Take out the attachment bolts. • Open the air cleaner box, remove the grille and the filtering part. 4 - 14...

  • Page 115: Recomposition Of The Air Cleaner

    UPDATES ENGINE C364M ENGINE C364M 4.5.3. RECOMPOSITION OF THE AIR CLEANER • Change the filtering part and reinsert the grille. • Tighten the air cleaner box attachment bolts. 4 - 15...

  • Page 116: Replacement Of The Air Cleaner Box

    UPDATES ENGINE C364M ENGINE C364M 4.5.4. REPLACEMENT OF THE AIR CLEANER BOX • Position the air cleaner box and connect it to the carburettor body and air intake sleeve. • Tighten the air cleaner box attachment bols and the carburettor body and air intake sleeve clamps. 4 - 16...

  • Page 117: Secondary Air System

    UPDATES ENGINE C364M ENGINE C364M 4.6. SECONDARY AIR SYSTEM 4.6.1. REMOVAL OF THE SECONDARY AIR SYSTEM • Unscrew the two attachment bolts and removal the aluminium secondary air system cover. • Remove the plastic cover and sponge cleaner. • Remove the seat of the one-way valves. Check the soundness of the valves and replace them in their seat.
  • Page 118 UPDATES ENGINE C364M ENGINE C364M 4 - 18...

  • Page 119: Replacement Of The Secondary Air System

    UPDATES ENGINE C364M ENGINE C364M 4.6.2. REPLACEMENT OF THE SECONDARY AIR SYSTEM • Replace the sponge filter and insert the plastic cover. • Insert the aluminium cover and tighten the attachment bolts. 4 - 19...

  • Page 120: Carburettor Body

    UPDATES ENGINE C364M ENGINE C364M 4.7. CARBURETTOR BODY 4.7.1. 1 REMOVAL OF CARBURETTOR • Slacken the clamps and detach the coolant pipes and the mixer-carburettor union pipe from the carburettor. • Stopper the three pipes. • Use a Torx spanner to loosen the manifold bolts and remove the carburettor body complete with the induc- tion manifold.

  • Page 121: Dismantling The Carburettor

    UPDATES ENGINE C364M ENGINE C364M 4.7.2. DISMANTLING THE CARBURETTOR • Loosen the clamp bolt and separate the carburettor from the manifold. • Unscrew the bolts and remove the protection, the bracket and the choke. • Unscrew the air-petrol dispenser cover and remove it. Remove the spring and its cable retaining cup.
  • Page 122 UPDATES ENGINE C364M ENGINE C364M • Unscrew the two bolts and remove the bowl of the car- burettor. • Make sure the carburettor is properly supported and remove the float complete with the needle valve by sliding out the float retaining pin. •...
  • Page 123 UPDATES ENGINE C364M ENGINE C364M • Remove the dispenser complete with needle and then the diffuser. • Remove the idling adjustment screw and the mixture adjusting screw. • Remove the idling adjustment screw and the mixture adjusting screw. 4 - 23...

  • Page 124: Reassembly And Checking Of The Carburettor

    UPDATES ENGINE C364M ENGINE C364M 4.7.3. REASSEMBLY AND CHECKING OF THE CAR- BURETTOR • Check that all the passages are free from dirt and then clean the jets and the diffuser. • Replace the idling adjustment screw and the mixture adjusting screw.
  • Page 125 UPDATES ENGINE C364M ENGINE C364M • Remount the float with its needle valve and insert the retaining pin in the float. Check that coupling plane of the float is parallel to the plane of the bowl with the carburettor upside down. •...
  • Page 126 UPDATES ENGINE C364M ENGINE C364M • Check that the plunger of the automatic choke is free from scratches and rust and slides freely in the seat of the bearing. • Use a gauge to measure the protrusion of the plunger and check that the value is correct.

  • Page 127: Replacement Of The Carburettor

    UPDATES ENGINE C364M ENGINE C364M 4.7.4. REPLACEMENT OF THE CARBURETTOR • Check that fins bearing is not worn and the support surfaces of the petals are not deformed4 • Position the fins support and the carburettor body complete with manifold and tighten the respective bolts.
  • Page 128 UPDATES ENGINE C216M ENGINE C216M UPDATES ENGINE C216M 5 - 1...
  • Page 129 UPDATES ENGINE C216M ENGINE C216M SUMMARY 5.1. INTRODUCTION .............................. 3 5.1.1. REFERENCE MANUALS .......................... 3 5.2. GENERAL TECHNICAL INFORMATION ......................4 5.2.1. TECHNICAL DATA............................ 4 5.2.2. TIGHTENING TORQUE TABLE ........................ 5 5.3. ENGINE ................................6 5.3.1. REMOVING COOLING CASE ........................6 5.3.2.

  • Page 130: Introduction

    UPDATES ENGINE C216M ENGINE C216M 5.1. INTRODUCTION 5.1.1. REFERENCE MANUALS ENGINE WORKSHOP MANUALS aprilia part# (description) 8140818 8140821 8140819 8140820 8140822 8CM0067 SPECIAL TOOLS MANUALS aprilia part# (description) H001 5 - 3...

  • Page 131: General Technical Information

    UPDATES ENGINE C216M ENGINE C216M 5.2. GENERAL TECHNICAL INFORMATION 5.2.1. TECHNICAL DATA ENGINE Model C216M Type 2 strokes - controlled ignition Number of cylinders horizontal single-cylinder Total displacement 49.38 cu. cm. Bore/stroke 40 mm / 39.3 mm Compression ratio 10.3 : 1 Starting electric + kick starter Engine idling speed...

  • Page 132: Tightening Torque Table

    UPDATES ENGINE C216M ENGINE C216M 5.2.2. TIGHTENING TORQUE TABLE DESCRIPTION ENGINE TRANSMISSION COVER Transmission cover screw 12 ÷ 13 DRIVE PULLEY Drive pulley nut 40 ÷ 44 Clutch housing nut 40 ÷ 44 CLUTCH Clutch nut 55 ÷ 60 CYLINDER HEAD Cylinder head nuts 10 ÷...

  • Page 133: Engine

    UPDATES ENGINE C216M ENGINE C216M 5.3. ENGINE 5.3.1. REMOVING COOLING CASE • Release and remove the four screws. • Move secondary air valve and remove fan cover • Release and remove the two screws. 5 - 6...
  • Page 134 UPDATES ENGINE C216M ENGINE C216M • Slide the oil hose to remove the cooling case. 5 - 7...

  • Page 135: Removing The Head

    UPDATES ENGINE C216M ENGINE C216M 5.3.2. REMOVING THE HEAD • Remove the cooling case. • Remove the exhaust system. • Unscrew and remove the spark plug. • Loosen and remove the two nuts, collect the two studs. • Remove the head. •...

  • Page 136: Flywheel Disassembly

    UPDATES ENGINE C216M ENGINE C216M 5.3.3. FLYWHEEL DISASSEMBLY • Remove the cooling case. • Release and remove the three screws. • Remove the cooling fan. • Lock flywheel by means of the specific wrench and remove flywheel hexagonal securing nut. •...
  • Page 137 UPDATES ENGINE C216M ENGINE C216M • Loosen and remove rpm-sensor screws - coolant inlet hose. • Remove the coolant inlet duct from its housing. • Loosen the screws and remove stator with wiring and rpm-sensor 5 - 10...

  • Page 138: Tightening Torque Settings

    UPDATES ENGINE C216M ENGINE C216M 5.3.4. TIGHTENING TORQUE SETTINGS CYLINDER HEAD Cylinder head nuts 10 ÷ 11 Spark plug fastener 11 ÷ 14 Injection head securing screw 3 ÷ 4 5 - 11...
  • Page 139 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com...

This manual is also suitable for:

C364mC216m

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