APRILIA M192M Workshop Manual page 13

GENERAL INFORMATION
GENERAL PRECAUTIONS AND INFORMATION
The following indications should be strictly complied with when servicing, disassembling or reassembling the engine.
DANGER
Never use naked flames when servicing. Before servicing or inspecting the motorcycle: stop the en-
gine and remove the key from the ignition switch; allow for the engine and exhaust system to cool
down; where possible, lift the engine using adequate equipment placed on firm and level ground. Do
not touch engine hot parts. Risk of scalds and burns.
Never put any mechanical parts or other engine components in your mouth when you have both
hands busy. None of the engine components is edible.
Unless expressly specified otherwise, install/reassemble by following removal/disassembly procedure
in the reverse order. Where a procedure is cross-referred to relevant sections in the manual, proceed
sensibly to avoid disturbing any parts unless strictly necessary. Never polish matte-finished surfaces
with abrasive substances.
Never use fuel as solvent to clean the engine.
Do not clean any rubber or plastic parts with alcohol, petrol or solvents. Clean with water and neutral
detergent.
When two or more persons are servicing the same motorcycle together, special care must be taken to
avoid personal injury.
Please read
BEFORE REMOVING OR DISASSEMBLING ANY COMPONENTS
• Clean off all dirt, mud and dust and clear any foreign objects from the engine before removing or disassembling any
parts.
•
Use the model-specific special tools where specified.
REMOVING OR DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to loosen and/or tighten nuts and bolts. Always use a suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection using
a distinctive symbol.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be refitted together. These parts have seated themselves against one another in service as
a result of normal wear and tear.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep away from heat.
INSTALLING OR ASSEMBLING THE COMPONENTS
DANGER
Used circlips or snap rings must always be replaced.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow
fitment to the shaft.
Make a rule to check that a newly –fitted circlip or snap ring is properly and firmly seated.
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 aprilia ORIGINAL SPARE PARTS only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten evenly
in subsequent steps until achieving the specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have a
damaged thread.
- Lubricate the bearings abundantly before assembly.
- Make a rule to check that all components you have fitted are correctly in place.
- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate the
motorcycle in a private estate area or in a safe area away from traffic.
- Clean all joint surfaces, oil seal edges and gaskets before assembly. Apply a light coat of lithium grease along the e-
dges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).
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Engines M192M / M191M / M245M / M234M / M282M / M281M
1.3.1 carefully.