Brochure: AF1 Sintesi 1989

 AF1 Sintesi 1989 brochure - unfortunately its not original copy but I am working on getting a high-res update. :-)

my bike, swing arm rebuild

After getting the swing arm powder coated I wanted to get it back on to the bike could get back on its wheels and I could have a shuffle about.

First thing was to get the main bearings (4) back in to the pivot, these are super snug so lots of grease is needed. TIP, place the bearings (4) in a freezer for 10 minutes then install them in to the swing arm. The cold will make the bearing contract a little and make installing them a little easier. Fit the O-rings (7) to each side of the roller bearing and grease liberally. At this point I put the pins also (5) in the freezer to shrink a little while the roller bearings expanded to their normal size. Next I just slid the pins (5) in the bearings (4), easy!
Next I installed the bearing shields (3) to each end, again with grease so they wouldn't easily drop off.

The next stage was to offer up the swing arm to the main frame and slide the main pivot axle (2) in to hold it there.

The next stage was to get the rear shock and the shock linkage fitted. The shock can go in via the top or bottom but you will have to raise and lower the swig arm at points to get every bolt it. Again grease all bearings, and plenty of it.

I re-fitted the rear hub then re-fitted the wheel to be able to move the bike around but it will need to come off again for power coating.

Note, the wheel has a boss (1) on it which mates to a cut out on the rear wheel, make sure you do this.

Lastly I fitted the chain slider.

Torque values. 

The workshop manual states torque values in daN.m- Dekanewton, where the more common values now are in Nm - Newton, the conversion is just one decimal point or x 10 for ease, I have included both.

Shock linkage bolts including the top shock mount (fig 88 + 89) = 5 daN.m or 50Nm

Main pivot = see fig.92 follow correct procedure:

• Complete unscrew the adjustment boss on the right hand side (3)
  
• Insert the pivot axle and screw it in a few turns
• Screw the adjustment boss (3) and torque to 1 daN.m or 10Nm
• Tighten the retaining lock nut (1) in using the notched Aprilia tool to 2.5 daN.m or 25Nm
• Tighten the main pivot axle to 8 daN.m or 80Nm

Wheel nuts = 8 daN.m = 80Nm

Main axle shaft nut (fig91, part 4) = 8 daN.m or 80Nm

this nut is torque to 80Nm, which may require an extension bar... 

main pivot requires a procedure to correctly tighten.

My bike, powder coating

As part of the freshen up I decided to powder coat the swingarm and rear sub frame. The swing arm is highly visible so desperately needed doing, where the subframe could of been rattle canned on the parts you can see, however it was a bit rusty in the parts you couldn't see so I wanted that addressed also.

I use a local powder coater to my work and I have used them before and been pleased with the results, check out http://www.plasticoat.co.uk/ if you are in the Portsmouth/ Gosport area. A good powder coater will mask all holes and bearing surfaces all you need to do is remove everything including bearings.

The colour I chose isn't the same as the original Aprilia colour, the original is more of a grey which over time looks quite drab especially next to the brilliance of the main frame and footrests. I went for a silver with a little sparkle like a Honda swing arm, I hope this will lift the bike a little and give it a slightly more premium look... I hope I am right about this!

Swing Arm

before

After

After

After

Subframe

Before

After

After

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My bike, chain sliders

The rubber chain sliders that fit to the upper and lower swingarm are no longer available, part numbers 8120491 (upper, 15) and 8120492 (lower, 16). My upper is salvageable but the lower is falling apart and they are essential for the finish of any restoration or if you intend on riding. Fortunately they are being reproduced in Italy via 3d printing and are readily available via ebay.

Ebay link

I'll update this post when I have some feedback on fit and finish. 

Join the new Facebook Aprilia AF1 group here: https://www.facebook.com/groups/apriliaaf1

my bike, decal kit

My decal kit arrived from Italy today from Decalmoto.com First impressions are that it looks fairly decent for the money, I'll give an update when I start to install it.

Note: The green looks more green in the flesh, maybe my camera/ office/ monitor makes it look more blue than it is? 

Join the new Facebook Aprilia AF1 group here: https://www.facebook.com/groups/apriliaaf1

AF1 Futura - Max Biaggi

Max Biaggi, the Roman Emperor needs no introduction but for those who need a refresher he is a 4 x 250cc Grand Prix World champion, 3 x Aprilia, 1 x Honda and 2 x World Super Bike Champion both on an Aprilia.  Max is most famous for his black Chesterfield Aprilia 250 but what people maybe don't realise is that Max cut his teeth in the ultra competitive Italian 125cc Sport Production championship and won it in 1990 on board an AF1 Futura.

At the recent Aprilia All Stars event at the Misano race track Biaggi stopped by the Duo Tempi Bei Tempi club stand to pose with and sign their Futura bike.

RSV250 Grand Prix bike

Biaggi on board the Futura

Biaggi's Af1 Futura

The Emperor 

Join the new Facebook Aprilia AF1 group here: https://www.facebook.com/groups/apriliaaf1

My bike, parts pull down and paint prep

In order to move this project on I have taken the nuclear option and applied to take the AF1 to Stafford in October as there is nothing like a deadline to create motivation!

First thing was to get the rear subframe and swingarm off and get them to the powder coaters. I hit a small hurdle in the fact I don't have the swing arm main pivot lock ring tool, but a screwdriver and hammer moved that. I removed the rear hub, rear shock then main swing arm pivot and then finally the swing arm.

With the swingarm off the chain sliders were removed and the lower one has broken, so replacements will need to be sourced, and the bearings removed for painting. 

Taking the back end off and seeing the wheels also confirmed I need to look at getting these painted also.

Other progress: I ordered the decal kit of e-bay and started to clean a lot of the loose parts.

a few chips on the rim, meaning these need paining 

rear subframe ready for painting

swingarm ready for painting

cleaning up the rear of the engine case and frame mount

rear shock and alloy rocker cleaned

Join the new Facebook Aprilia AF1 group here: https://www.facebook.com/groups/apriliaaf1