TECHNICAL COMMUNICATION A_210393_RC_EN

13/04/2021

Model: Aprilia RS 660 and Tuono 660
Subject: Exhaust valve clearance - Technical update
Campaign Code: PA0ZZQ2101_Stock
Campaign Code: PA0ZZQ2101_Sold

Dear Dealer / Service Centre,
through the ongoing, stringent quality control activities we perform on the components
installed on our vehicles and our continuous research to develop better new technical
solutions, in keeping with our commitment to ensure the best ownership experience possible
for the customer, it has come to our attention that it is necessary to check and, if necessary,
correct the exhaust valve clearance on the aforementioned vehicles to prevent the possibility
of valve noise during engine operation.
During this procedure, the special screw with seal of the timing chain tensioner and the oil
plug with seal must be replaced with new parts.
Please determine which vehicles in your stock or sold by you require this update, and:
Update all vehicles in stock before sale.
update vehicles that have already been sold at the first available opportunity.
As usual, the list of frame numbers involved in the campaign is viewable in the section
Campaigns / Campaign Reports of the PWM warranty management software suite.
Please contact the Technical Help Desk of our Technical Support Service for any queries or
assistance.

The update procedure to be carried out on the motorcycles involved differs depending
on the status of the motorcycle indicated in the SAP/PWM management system at the
time of launch of the technical update campaign (vehicles in stock or registered/sold
vehicles).

Page 1 of 13

1. Unsold vehicles (stock):
Technical Update with campaign code: PA0ZZQ2101_Stock
 The calibrated pads of the exhaust valves must be replaced on these valves.

2. Registered and sold vehicles (including demo vehicles):
Technical Update with campaign code: PA0ZZQ2101_Sold
 On these vehicles, it is necessary to replace the calibrated pads and, if necessary, also
the stop caps and the respective semi-cones. In the latter case, it may also be
necessary to replace the exhaust valve/s.

PROCEDURE IN PWM
From the main menu, select the option “campaigns”, then select the option “Enter
campaigns” from the sub-menu.
Enter the frame number subject to the recall campaign/technical update in the window
now opened.
Press “search” to open a window listing the service coupons available in relation to the
status of the frame number at the time of launch of this update:

(for vehicles with status 'stock' -> PA0ZZQ2101_Stock)


Coupon: Updating exhaust valve calibrated pads

Service coupon relative to the procedure for replacing the calibrated pads, and
reimbursing for the costs of the labour necessary for the procedure;

(for vehicles with status 'sold/registered/demo' -> PA0ZZQ2101_Sold)


Coupon 1 Checking and updating exhaust valve calibrated pads

Service coupon relative to the procedure for replacing the calibrated pads of the
exhaust valves, and reimbursing for the costs of the labour necessary for the
procedure;

Page 2 of 13



Coupon

2 Checking

and

updating

exhaust

valve timing

system

components;
Service coupon relative to the procedure for replacing the calibrated pads, stop caps
and semi-cones of the exhaust valves, and reimbursing for the costs of the labour
necessary for the procedure;



Select the coupon, compile the “Km” field, and then save the procedure definitively.
Note that in order to receive reimbursement for the procedure, the procedure must be
declared “completed” (as confirmed by status in PWM management system) within 6
months of the date of entry of the coupon.

MANDATORY ATTACHMENT FOR ALL SERVICE COUPONS:
The specific xls file, compiled correctly with the sizes of the shims used for the procedure,
must be attached to the service coupon entered.
Use the xls file downloadable from the link at the end of this technical note.
Example:
Cylinder 1 (Left)
Exhaust valve
Exhaust valve
(Outer)
(Inner)

Cylinder 2 (Right)
Exhaust valve
Exhaust valve
(Inner)
(Outer)

Thickness of original
pad
Thickness of pad used
for update procedure

LABOUR AND SPARE PARTS FOR PROCEDURE (for vehicles with status 'stock')
Coupon: Updating exhaust valve calibrated pads
Minutes of labour envisaged for procedure: 275’
Spare part no.: kit p/n 2R000553 + (1A013477 - 1A020131 - 1A015611 - 1A020131) see
table with details of kit on page 6

Page 3 of 13

LABOUR

AND

SPARE

PARTS

FOR

PROCEDURE

(for

vehicles

with

status

'sold/registered')
Coupon 1 Checking and updating exhaust valve calibrated pads;
Minutes of labour envisaged for procedure: 275’
Spare part no.: kit p/n 2R000553 + (1A013477 - 1A020131 - 1A015611 - 1A020131) see
table with details of kit on page 6

Coupon 2 Checking and updating exhaust valve timing system components;
Minutes of labour envisaged for procedure: 515’
Spare part no.: kit p/n 2R000554 + (1A013477 - 1A020131 - 1A015611 - 1A020131) see
table with details of kit on page 7
NOTE: For this activity ONLY, the costs incurred for the engine oil and coolant used in the
procedure are calculated at a flat rate, and the reimbursable labour costs are adjusted (515
minutes) to include these costs.

PAD KIT 2R000552
The calibrated pads required for this procedure will be shipped to you directly by
aprilia in sets consisting of an assortment of 10 sizes (with 4 pads per size), in suitable
quantities for the number of vehicles associated with your dealer code (obtained from
SAP/PWM).

DETAILS OF PAD KIT
Quantity of kits shipped to dealer
PAD KIT

No. of vehicles assigned to dealer

1 KIT

2 KITS

No. of KITs =
30% vehicles
assigned to
dealer

1 TO 2

3 TO 7

>7

CM327013

Pad, thickness 2.05

4

8

≥ 12

CM327015
CM327017
CM327019
CM327021
CM327023
CM327025
CM327027
CM327029
CM327031

Pad, thickness 2.10
Pad, thickness 2.15
Pad, thickness 2.20
Pad, thickness 2.25
Pad, thickness 2.30
Pad, thickness 2.35
Pad, thickness 2.40
Pad, thickness 2.45
Pad, thickness 2.50

4
4
4
4
4
4
4
4
4

8
8
8
8
8
8
8
8
8

≥ 12
≥ 12
≥ 12
≥ 12
≥ 12
≥ 12
≥ 12
≥ 12
≥ 12

Page 4 of 13

N.B : as an alternative to the thicknesses shown in the table, pads increased by 0.02 mm
could be shipped with the same code (Example: 2.07 mm instead of 2.05 mm).

Unused pads must be returned to aprilia or kept by you for use for this procedure on other
vehicles assigned to you.

Page 5 of 13

A flow chart for handling this campaign is given below
'Stock' vehicles:


Service coupon 'Updating exhaust valve calibrated pads' (chain tensioner screw and oil plug)

'Sold' vehicles:
1. Service coupon 'Updating exhaust valve calibrated pads' (chain tensioner screw and oil plug)
2. Service coupon 'Checking and updating exhaust valve timing system components' (chain tensioner
screw and oil plug)

y
Vehicle is involved
in
campaign

STOCK

Vehicle
status

> 0.05 mm

Select service coupon Updating
exhaust valve calibrated pads

Kit 2R000553
2R000553

Select Service coupon 1
Checking and updating
exhaust valve calibrated pads

Kit 2R000553
2R000553

SOLD

Check valve
clearance*

< 0.05 mm

Replace the exhaust valve(s) if necessary
(carry out leak test)
to be ordered under warranty
and
Select service coupon 2 Checking and
updating exhaust valve timing system
components

If possible, replace the special
screw with seal of the timing chain
tensioner

Kit 2R000554

1A015611 + 1A020131

If possible, replace oil plug with
seal

1A013477 + 1A020131





Procedure
completed
Page 6 of 13

Enter Service coupon 1
(clearance > 0.05 mm) ONLY if
ALL valves respect this value.
Enter Service coupon 2
(clearance < 0.05 mm) if AT
LEAST one of the exhaust valves
is in this condition.

Table with details of spare parts included in “kit for Technical Update campaign for 660
engines” p/n 2R000553
The KIT described below and the pads received directly from aprilia (see page 4) are
required for implementing the campaign on vehicles with status 'stock' or vehicles with
the status 'sold/registered' (depending on the valve clearance measured).