DETAILS OF KIT 2R000553
Spare parts list
1
2
3
4
5
6
7
8

Description
Head cover gasket
Spark plug gasket
Damper bush
Flat washer for chain tensioner plug
Flanged button head screw for timing sprocket
Clutch cover gasket
Plastic clamp
Blow-by click clamp

Page 7 of 13

Part No.

Q.ty per
vehicle

1A011919
1A012849
898410
016661
1A013092
1A013509
2D000676
CM001905

1
2
4
1
2
1
1
1

Table with details of spare parts included in “kit for Technical Update campaign for 660
engines” p/n 2R000554
The KIT described below and the pads received directly from aprilia (see page 4) are
required for implementing the campaign on vehicles with status 'sold/registered'.

DETAILS OF KIT 2R000554
Spare parts list
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Description
Upper exhaust valve stop cap
Semi-cone
Head cover gasket
Spark plug gasket
Damper bush
Oil drain plug gasket
Aluminium washer for water pump screw
Exhaust gasket
Cylinder/head gasket
Chain tensioner O-ring
Flat washer for chain tensioner plug
Flanged button head screw for timing sprocket
Clutch cover gasket
Plastic clamp
Blow-by click clamp

Part No.

Q.ty per
vehicle

1A020955
857024
1A011919
1A012849
898410
831393
847239
852090
1A011923
857176
16661
1A013092
1A013509
2D000676
CM001905

4
8
1
2
4
1
1
2
1
1
1
2
1
1
1

OPERATING PROCEDURE
Secure the vehicle in a stable, safe position and follow the specific instructions either for
'stock' vehicles (vehicles involved in campaign with an unsold status indicated in management
system at the time of launch of this update) or for 'sold' vehicles (vehicles involved in
campaign with the status 'sold/registered' indicated in management system at the time of
launch of this update).

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'Stock' vehicles (unsold)
Replace the calibrated pads of the 4 exhaust valves, following the instructions given in the
paragraph “Important” below exactly as indicated.

Important
Replace the original calibrated pad of each exhaust valve with an appropriate new pad
selected from the pad kit/s received directly from aprilia.
Select the correct pad thickness with the following procedure. After removing the pad
originally installed in the engine, fit a new pad from the pad kit of the smallest measurement
available and
measure the exhaust valve clearance again. Repeat the last two steps as necessary (using
the next largest pad size if the clearance is not correct) until the clearance is between 0.10
mm and 0.20 mm.
For all other information, more detained operating instructions and the tightening torques
applicable for the individual parts, see the service station manual for the aprilia RS660.
NB: if a valve clearance within the range from 0.10 to 0.20 cannot be attained using any
of the calibrated pads supplied in the kit, a valve clearance of up to 0.22 mm is
permissible.

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Sold/registered vehicles (including demo vehicles)
Measure the clearance of the 4 exhaust valves with the original calibrated pads still installed,
referring to the chapter Maintenance in the service station manual for the aprilia RS660.
PROCEDURE FOR INDIVIDUAL VALVE
 If the clearance detected is less than 0.05 mm and the valve leak test is negative,
carefully follow procedure A described below;
 If the clearance detected is less than 0.05 mm and the valve leak test is positive,
carefully follow procedure B described below;
 If the clearance measured is greater than 0.05 mm, carefully follow procedure C
described below.

Clearance < 0,05 + negative valve leak test
Clearance < 0,05 + positive valve leak test
Clearance > 0.05 mm

Valve 1
A
B
C

Valve 2
A
B
C

Valve 3
A
B
C



Procedure A -> Replacing Valve + Stop cap + Semi-cones + Pad



Procedure B -> Replacing Stop cap + Semi-cones + Pad



Procedure C -> Replacing Pad

Valve 4
A
B
C

Valve leak test:
Carry out the leak test for each valve where the clearance is less than 0.05 mm; this test will
determine the quality of the valve seal on its seat; in fact, remember that if the valve has
operated with zero clearance, the seal between the valve and the valve seat could have been
compromised.

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Procedure (A)
Replace the exhaust valve complete with O-ring, on which the leak test gave a negative
result (to be requested via warranty), as it could have been compromised, together with the
semi-cones, stop cap supplied in KIT 2R000554 and the calibrated pad to be chosen from
those sent with KIT 2R000552 (preferring the smaller size).
Measure the exhaust valve clearance again. Repeat the last two steps as necessary (using
the next largest pad size if the clearance is not correct) until the clearance is between 0.10
mm and 0.20 mm.
For all other information, more detained operating instructions and the tightening torques
applicable for the individual parts, see the service station manual for the aprilia RS660.
NB: if a valve clearance within the range from 0.10 to 0.20 cannot be attained using any
of the calibrated pads supplied in the kit, a valve clearance of up to 0.22 mm is
permissible.

Procedure (B)
If the exhaust valve has a clearance of less than 0.05 mm, and the leak test gave a positive
result, replace the semi-cones and stop cap with the parts included in KIT 2R000554 and
replace the calibrated pad with a new pad from the pad KIT 2R000552 of the smallest
measurement available.
Measure the exhaust valve clearance again. Repeat the last two steps as necessary (using
the next largest pad size if the clearance is not correct) until the clearance is between 0.10
mm and 0.20 mm.
For all other information, more detained operating instructions and the tightening torques
applicable for the individual parts, see the service station manual for the aprilia RS660.
NB: if a valve clearance within the range from 0.10 to 0.20 cannot be attained using any
of the calibrated pads supplied in the kit, a valve clearance of up to 0.22 mm is
permissible.

Page 11 of 13

Procedure (C)
Replace the original calibrated pad with a new pad from the pad 2R000552 of the smallest
measurement available.
measure the exhaust valve clearance again. Repeat the last two steps as necessary (using
the next largest pad size if the clearance is not correct) until the clearance is between 0.10
mm and 0.20 mm.
For all other information, more detained operating instructions and the tightening torques
applicable for the individual parts, see the service station manual for the aprilia RS660.
NB: if a valve clearance within the range from 0.10 to 0.20 cannot be attained using any
of the calibrated pads supplied in the kit, a valve clearance of up to 0.22 mm is
permissible.

Regardless of the status of the vehicle (stock or sold/registered), if possible, the special screw
with seal of the timing chain tensioner and the oil plug with seal should also be replaced
during the procedure described above to improve the seal tightness of these components
(see table with details of kit and excerpt from spare parts table).

Reimbursement for the labour costs incurred for the following activities is already included
in the labour time envisaged and reimbursed by the service coupons indicated previously.

Spare part no.: ordered and shipped automatically upon selection of service coupons
indicated above
Threaded plug
Bonded seal washer

1A013477

1

1A020131

1

Special screw
Bonded seal washer

1A015611

1

1A020131

1

Page 12 of 13

Details of kit

Spare parts
catalogue ref.

Description

Part No.

Q.ty per
vehicle

11 Tab. A

Threaded plug

1A013477

1

12 Tab. A

Seal washer

1A020131

1

13 Tab.B

Special screw

1A015611

1

12 Tab.B

Seal washer

1A020131

1

Tab A (part 11-12)

Tab B (part. 12-13)

Tightening torque: 25 Nm

Please do not hesitate to contact the Technical Support Service for any queries.

Best regards,

Piaggio & C. SpA
Business Unit Aftersales
Operations & Technical Service

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