24203C Antihopping clutch kit APRILIA RS660 - mounting instructions

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

This clutch should be installed by an Aprilia service center, or experienced mechanic.

1. Read these instructions with photos before you start. Check that the kit includes all parts.
2. Remove the old clutch (according to Aprilia workshop manual), clean the threads on the shaft of old glue perfectly. Clean with brake cleaner.
3. Make sure the original thick shim under clutch drum is in it´s position ( pic.a).
4. Install this pre mounted unit to gearbox shaft ( pic.b ).
5. The kit includes the small parts that are necessary for assembly. They are packed in position how to mount them. Mount the spring shim at first (pic.c ) and the OEM nut (pic.d ). Tighten the nut to 175 Nm, use glue Loctite No. 620 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 ). Caution when installing the clutch plates !!! The plates in pic.g do not get installed. Replace them with plates from kit following way: The 1st friction plate with the larger ID and judder rings is replaced by one friction plate from kit. The last two friction plates and one steel plates are replaced with clutch plates from the kit. ( pic.h )
7. Remove the pull rod from original pressure plate and transfer it to kit pressure plate. Install 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 via the small holes in the pressure plates. The correct clearance is about 1,0 mm, minimal clearance is 0.6mm. When the clutch plates wear to this point, install new friction plates.
9. Install clutch cover according to the Aprilia workshop manual, adjust clutch cable and go back to track.

LIST OF PARTS

1 pc. clutch hub assembly

1 pc. presure plate

1 pc. spring washer

1 pc. steel plate

3 pc. friction plate 2.3mm

5 pcs. spring retainer basic

5 pcs. spring retainer for high preload

5 pcs. M5 x 25 bolt