EVO Shift Kit 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 32mm socket
7. A small ziptie
|This is where you will
The stock detent star and detent arm are shown.
Ziptie the spring loaded fingers back towards the shift shaft. It makes it easier to remove and replace the shift star.
|Shift the bike by moving
the shift star till it reaches the limits to the shift drums rotation
(it will feel solid i.e. "metal to metal).
You'll have to rotate the transmission shaft in both directions to get it to shift through all the gears.
Use a 5mm allen wrench turn the shift drum. When you
reach the "end" of shift drum rotation, loosen up he allen.
The picture shows a very short 3/8" drive 5mm allen wrench.
to lever the
detent arm roller
away from the shift star.
Makes removing the star a bit easier.
|Removal of the stock star.|
|On it's way to a new
home where old friend Notchy Shift joins a Witness Protection program....
Remove the stock detent arm.
|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.
You will have to rock the clutch shaft back and forth
to let the gear engagement dogs and slots to line up to complete each shift.
If it doesn't shift through all the gears, something's not aligned
in the shift mechanism.
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!