Aprillia, Mille, 1000, fuel injection, tuning, factory pro, carburetor, shift, ignition

Aprilia EVO Shift Kit Install
If this intimidates, you..... 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 (for "stuff") and 2. New Aprilia clutch cover, water pump gasket (not supplied) (you have 90% probability you can reuse originals, but I'm not that lucky?) 3. Normal mechanic's tools 4. 5mm allen wrench 5!!! 1/2" Impact wrench (for 32mm clutch nut) 6. std depth 32mm socket 7. A small ziptie
This is where you will be working. 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. (It will be either 1st or 6th gear) The picture shows a very short 3/8" drive 5mm allen wrench.
Magic!
Use a screwdriver 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. (you are probably wondering why we didn't take off the detent arm before we took off the star..... So am I!)
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). Tighten. Note that the stock detent arm doesn't need to be installed while you are installing the Shift STAR. Good idea to use a drop of LocTite - but not absolutely required if you actually tighten the screw properly. (6-8ftlbs torque).
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. Goes like this: Rotate shift drum - It goes about 51% of the way, then the detent rotates some more (because of the spring loaded detent arm, but not all the way to the STAR valley, then rotate the clutch shaft back and forth, and then, when the dogs and slots line up, the STAR will rotate the rest of the way, till the detent arm is in the valley. "Snick". Repeat for each gear. Go 1st through 6th and back down a few times. If it doesn't shift through all the gears, something's not aligned in the shift mechanism. Click here to view a trained professional do it. "Rotax transmission gear change!" 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. Now, do like the movie star mechanic did - Reach under or over the bike and use the shift lever to make the changes. This checks the shift arm operation.
All OK? Put all the rest of this stuff back on. Definitely use LocTite on the clutch nut and torque to factory Aprilia specs. Remember! Your Aprilia Shop Manual is the Last Word in assembly procedures! If in doubt at all - do what your manual says.
Do all safety checks necessary. Test ride carefully! Any problems? Call 800 869-0497 ask for Tech Enjoy your new sweet shifting! Marc Salvisberg comments / corrections / additions?