APRILIA RS660 - mounting instructions

Congratulation, you bought the best clutch systems for your RS660.

This clutch needs to be installed by an experienced mechanic.

1. Read this instruction with photos before you start. Check if the kit includes all parts .

2. Remove the old clutch (according to Aprilia workshop manual), clean the threads on the input shaft of old glue perfectly. Clean with brake cleaner.

3. Check, if the original thick shim under clutch drum is in its position ( pic.a).

4. Install the clutch hub unit to gearbox shaft ( pic.b ).

5. The kit includes all small parts that are necessary for assembly. They are packed in position as to how to mount them. Mount the spring shim at first (pic.c ) and the OEM nut (pic.d ). Nut torque moment 175 Nm, use glue Loctite No. 620 (Red) to secure it ( pic.e, f )

6. Install the clutch plates and springs. This clutch is designed for OEM plates and kit springs ( CBR600RR style ). Observe the installing order of clutch plates !!! Some OEM plates have to be replaced by other OEM ( RS 660 ) plates according to following chart ( clutch plates to be replaced are on pic. g )

Correct total thickness is to be about 44.3mm. Check the hub / pressure plate height later, when complete clutch is assembled.

7. Remove pull rod from STD pressure plate and put to kit pressure plate. Mount the this pressure plate with pull-rod (pic.i ). Install clutch springs with kit retainers and M5x

25mm kit bolts ( torque 8 Nm ) ( pic.j, k )

8. Check the clearance between pressure plate and clutch hub in pressure plates hole. The correct clearance is for new clutch plates 0.9 – 1.2 mm. In case of smaller clearance, replace one friction plate 2A000927 with friction plate 1A010611 which increases the clearance by about 0.5mm