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Thread: Clutch Pack

  1. #1
    apriliaforum expert bros400pgm's Avatar
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    Clutch Pack

    Anyone know what is the total thickness of a new clutch pack, which consists a pack of 10 steel plates AP8106915 and a pack of 9 lined discs AP8106867?
    I had bought them 4 years ago and did not measure them, nor i can find anything for them and 2 different engine manuals i have are writing complicated things.
    I am trying to figure out what the service limit is for this pack.

  2. #2
    apriliaforum expert DanV990's Avatar
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    Wear limit is 46.3mm for the clutch stack height of 10 steel and 9 friction plates.
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  3. #3
    apriliaforum expert bros400pgm's Avatar
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    Another manual states that wear limit is 44.9mm
    And i know that older rotax engines had different clutch baskets than the new ones.



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  4. #4
    apriliaforum expert DanV990's Avatar
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    44.9mm is from the Gen 1 1998-2003 manual

    46.3mm is from the Gen 2 2004-2009 Manual

    I have both manuals and specifically made sure to quote from the Gen2 manual beacuse your profile and your photo state you have a 2004 Gen 2 bike.
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  5. #5
    apriliaforum expert bros400pgm's Avatar
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    No sorry. It is for my other bike, a 2001 caponord. Which is almost identical to newer capos, from 2004 onwards. That is why i am confused

  6. #6
    apriliaforum expert DanV990's Avatar
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    Looking at the parts fiche it seems the same parts can be used in both Gen 1 and Gen 2 bikes so not sure why the different stack heights are listed. It seems the difference may be in the final staggered steel plate for the gen 2 bikes based on this page from AF1.

    http://www.af1racing.com/store/Scrip...idProduct=4622
    Adige 1000cc Clutch Kit*
    Designed as an OEM replacement. Adige is an occasional OEM parts supplier to Aprilia and Rotax, so this clutch kit is essentially an OEM piece, albeit at a reduced price versus Aprilia's retail.
    Minimum stack height is 44.9mm for all '98-'03 Mille, Mille-R, '00-'03 Falco, '01-'04 Futura, '01-'03 CapoNord, '02-'05 Tuono.
    Minimum stack height is 46.3mm for all '04-'09 RSVR, RSVR Factory, '06-'10 Tuono, '04-'07 CapoNord.
    Kit contains carbon fiber frictions, steels, but DOES NOT include springs. See the right margin of this page for OEM replacement springs. Quantity of six required.
    Note for 1998-2001 Falco or Mille, Mille-R owners: If you are experiencing clutch slippage, and have engine number 689953 and below, you first need the updated pressure plate (part #0259517) as seen on the right margin of this page.
    *Please Note: '04-'09 RSVR, RSVR Factory, '06-'10 Tuono, and '04-'07 CapoNord owners must re-use the final staggered steel (the one closest to the pressure plate).
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  7. #7
    apriliaforum expert bros400pgm's Avatar
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    I came across this and i had seen the differences in clutch baskets, as manual describes them, that is why i need to know the total thickness when new.
    Mine is at the moment on 46.6mm thickness so I assume that 46.3 is the minimum but i also want to know how much wear it has and if i can go down to 44.9mm

  8. #8
    apriliaforum expert DanV990's Avatar
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    The way I understand it you can't go down to 44.9 on your bike. It looks like the Gen 2 bikes uses a thicker staggered steel so the min would be 46.3mm
    The Page for the Barnett clutch pack states it more clearly
    http://www.af1racing.com/store/Scrip...?idProduct=880
    Minimum stack height is 44.9mm for all '98-'03 Mille, Mille-R, '00-'03 Falco, '01-'04 Futura, '01-'03 CapoNord, '02-'05 Tuono.
    Minimum stack height is 46.3mm for all '04-'09 RSVR, RSVR Factory, '06-'10 Tuono, '04-'07 CapoNord.
    Note for 1998-2001 owners: If you are experiencing clutch slippage, and have engine number 689953 and below, you first need the updated pressure plate from your dealer (part #0259519)
    *Please Note: '04-'09 RSVR, RSVR Factory, '06-'10 Tuono, and '04-'07 CapoNord owners may need to re-use the final staggered steel (the one closest to the pressure plate). Re-using the steel ensures proper stack height.
    1985 Honda VF500F Interceptor Red
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  9. #9
    apriliaforum expert bros400pgm's Avatar
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    Yes i understand what you are saying, thing is that i use a clutch pack which is designed for newer engines on an old engine, or may I say it right, on an old design clutch basket. The differences in wear limits, is probably to the diffrence in baskets?
    And thing is that when i installed the pack it fitted properly on the hub without the last steel plate being outside of the inner hub.
    Barnett and adige, probably need to use 11 steel discs or ditch one steel and replace it with the staggered one?

  10. #10
    apriliaforum expert DanV990's Avatar
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    Sorry I missed the post where you said it was for a 2001 Caponord. For the 01 Capo 44.9 would be the limit. 10 steels is the number to use not 11. Difference in heights appears to be the final steel that goes closest to the pressure plate and is staggered. Check your stack on the new one and see if it has one steel that is thicker than the others. If they are all the same then it should go in your Capo without issue.
    Last edited by DanV990; 05-22-2014 at 10:46 AM.
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  11. #11
    apriliaforum Junkie upex's Avatar
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    Ha, I replaced my frictions a while back and the stack height was too big, couldn't get it all in, so had to change the steels for another set that were a good few mm thinner, bet this was why, gen 2 pack in a gen 1 basket,
    Correlation is not always causation.

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  12. #12
    apriliaforum Junkie BigK's Avatar
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    I know this is an old thread. I'm reading a lot about minimum stack height. I have an '03 Tuono with just under 60K on her. Just got a new Barnett kit from AF1 . So I see the minimum height, but is there a maximum , in order to keep it from dragging? All of his talk about Barnett makes me wonder if I made a bad choice. I've alway heard of how great theses are and are considered an upgrade from stock. I have had the bike for 10 years without a clutch issue,and I don't want to create one. Thoughts?
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