RSV4 Shift Spring Install
|If this intimidates,
Slowly step back away from the 1/2 air impact wrench......
|This is what stuff
you take off.
(covers, water pump, etc)
and you need.....
1. Aprilia Shop Manual
3. Normal mechanic's tools
4. 5mm allen wrench
5!!! 1/2" Impact wrench
6. std depth 27mm socket
7. new clutch cover gasket
|Remove the clutch cover and secure out of the
Careful, the starter idle gear usually falls out.
|Carefully remove the 6 5mm headed clutch allen
Sometimes the steel bolt "post" unscrews with the clutch screw - No matter, you can take the post and screw apart later and loctite the post into the clutch hub.
|Remove the outer pressure plate.
|Note the staggered semi-circles on the clutch
Keep that relationship (look at the Aprilia Service manual).
I'm sure there's some magic in the setup but it appears that every 2 change. Or there's an snickering engineer overseas who likes red herrings.
|Now, remove the 27mm clutch nut. It's "normal"
thread. Be sure to "unstake" the nut flange (if yours is staked).
Under the nut is a thrust washer (check that in the manual, I'm doing this from memory) and the slipper clutch 3 legged spring.
You can see, at 7 o'clock, that one of our "clutch spring posts" unscrewed with the clutch screw.
|Set the new Factory
Pro Shift STAR in place - using that screwdriver to keep the detent arm
down while you place the STAR into it's "only fits one way" slot -
When roughly in place, thread in the retaining screw in and rotate the Shift STAR until you feel it drop into it's shift drum slot.
It doesn't have to be in any particular gear position.
(in case you were wondering)
Rotate the shift star till it reaches the end of it's
travel (it will be 1st or 6th).
Good idea to use a drop of LocTite - but not absolutely
required if you actually tighten the screw properly.
|Now let's install the
new Factory Pro Microbearing Detent Arm.
Best to assemble the stack of shims, arm and spring onto the screw and thread the screw in just enough to hold things and lever the arm up, onto the profile of the STAR.
This picture shows what notch happens to be neutral. It's the 1/2 depth "valley".
LocTite is fine. 6-8 ftlbs torque
|Check that the bike
shifts through all the gears.
If it doesn't shift through all the gears, something's not aligned.
Click here to view a trained professional do it.
"Rotax transmission gear change Wild Ride!"
He happens to be shifting with the shifter, but I would leave the ZipTie on, and use the 5mm allen screw in the Shift STAR to turn the shift drum to check STAR / drum indexing.
All OK? Snip that ZipTie and let the shift arm
finger reach over and caress the Star's pins.
Put all the rest of this stuff back on.
Definitely use LocTite on the clutch nut and torque to factory Aprilia specs.
If in doubt at all - do what your manual says.
safety checks necessary. Test ride carefully!
Any problems? Call 800 869-0497 ask for Tech
Enjoy your new sweet shifting!
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