Recall 21V502 affects 308 2021 Aprilia Tuono 660 and RS 660 motorcycles for connecting rod failure. Repair is free at any franchised Aprilia dealer.
Aprilia is recalling 308 2021 Tuono 660 and RS 660 motorcycles because the engine crankshaft connecting rod was improperly heat-treated and can break. A broken connecting rod can cause a sudden engine stall and increase the risk of a crash; Aprilia dealers will complete the recall repair free of charge.
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What's wrong?
The crankshaft connecting rod in the 2021 Aprilia Tuono 660 and RS 660 is the metal link between the piston and the crankshaft. It turns the piston's up and down movement into rotation, so the engine can send power through the motorcycle's drivetrain. The rod has to stay strong under constant heat, speed, and engine load.
On affected motorcycles, a specific batch of connecting rods did not receive the required heat treatment. That process is supposed to give the metal the right strength. Because the treatment did not meet Aprilia's specifications, the rod can break while the engine is running. The affected connecting rods have the stamping code "DA" on the part.
The warning sign is engine noise before breakage. If the engine starts making unusual mechanical noise, stop riding and contact an Aprilia dealer before running the motorcycle again.
Who's affected?
The Tuono 660 and RS 660 share the same engine component concern: crankshaft connecting rods.
| 2021 Aprilia Tuono 660 | Engine |
|---|---|
| 2021 Aprilia RS 660 | Engine |
| Units affected | 308 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether your specific motorcycle is included.
What's the safety risk?
A broken connecting rod can stall the engine without time to recover, increasing crash risk. Engine noise comes before breakage, so treat new or worsening noise as a reason to stop riding and call an Aprilia dealer. Repair is free at any franchised Aprilia dealer.
What should I do?
- Check your VIN to confirm your 2021 Aprilia Tuono 660 or RS 660 is included in this recall.
- Contact a franchised Aprilia dealer to schedule the free engine replacement that addresses the improper connecting-rod heat treatment and sudden engine stall risk.
- Bring the owner letter if you have it, or reference recall number 21V502 when you call.
- Ride cautiously until the repair is complete, and leave extra room to pull off if the engine stalls.
- Call Aprilia customer service at 1-212-380-4400 with recall questions.
What happens at the repair
At the dealer, an Aprilia technician replaces the engine covered by recall 21V502. The replacement engine, parts, and labor are free under the recall. This is the repair for the improperly heat treated crankshaft connecting rod in the 2021 Tuono 660 and RS 660 engines. Aprilia has a general reimbursement plan on file, so owners who already paid for the same engine repair before the recall notice should contact Aprilia customer service and ask what documentation the plan requires.
| Reimbursement | Reimbursement available |
|---|
Timeline
| July 1, 2021 | NHTSA published the recall |
|---|---|
| July 2, 2021 | Dealer notification began |
| July 2, 2021 | Dealer notification ended |
| July 7, 2021 | Interim owner notification (was planned for this date) |
| July 9, 2021 | Owner notification mailed |
Frequently asked questions
What is recall 21V502?
Recall 21V502 covers 308 2021 Aprilia RS 660 and Tuono 660 motorcycles with an engine crankshaft connecting rod that was improperly heat-treated and can break. A broken connecting rod can stall the engine suddenly and increase crash risk. Aprilia dealers will replace the engine for free.
What should I do if my 2021 Aprilia Tuono 660 or RS 660 is on this recall?
Check your VIN to confirm your specific motorcycle is included in recall 21V502. If it is, contact a franchised Aprilia dealer to schedule the free engine replacement. Reference recall number 21V502 and Aprilia recall PA2ZZQ2107 when you call.
Is the recall repair free?
Yes. Federal recall law requires manufacturers to repair safety defects at no cost, and Aprilia will replace the engine free of charge at any franchised Aprilia dealer.
Is it safe to ride before the repair?
The recall involves a connecting rod that can break and cause a sudden engine stall, increasing crash risk. Aprilia has not issued a do-not-drive order in this recall, but affected owners should schedule the free engine replacement promptly and ask the dealer for guidance before riding.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/21V502000 |
|---|---|
| Aprilia customer service | 1-212-380-4400 |
| NHTSA recall # | 21V502 |
| NHTSA recall # (full) | 21V502000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Quarterly Report (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →