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Thread: V7 Clutch Rod and Throw-Out Bearing Replacement

  1. #1
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    V7 Clutch Rod and Throw-Out Bearing Replacement

    We've started seeing a few V7 customers coming in with the complaint of sticking or difficult to engage clutches on V7's, V7 II's, and V9's.

    The issue is most commonly the clutch throw out bearing, inner bushing, and rod, as described below.

    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:33 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  2. #2
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    V7's require a looser than normal clutch lever freeplay setting than most bikes. If adjusted too tight (in other words, not enough clutch lever freeplay) the small disk shaped V7 roller bearing will eventually be crushed and fail. When this happens the clutch bushing it rides on and the clutch pushrod are frequently ground down, and should also be replaced:

    Bad bearing, and worn down bushing and rod (note the missing rollers and brown burn marks on the rod; this rod was actually worn down some 4mm shorter than standard):

    Click image for larger version. 

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    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:34 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  3. #3
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    To begin, remove the clutch cable from the handlebar perch so that it is completely free, as seen below:

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    Last edited by Steve / AF1 Racing; 11-04-2016 at 01:26 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  4. #4
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Begin to remove/loosen the swingarm:

    1. Clamp the front wheel so the bike can not roll forward or backward

    2. Support the weight of the rear of the bike by lifting from the frame crossmember beneath the footpegs. (The bike should be supported so that the rear wheel is just barely in contact with the ground and can be spun with relatively little hand force.
    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:37 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  5. #5
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Loosen the bellows clamp on the driveshaft at the transmission mount:

    Name:  rod3.jpg
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    Last edited by Steve / AF1 Racing; 11-04-2016 at 01:29 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  6. #6
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Loosen and let hang from the top mounts the RH and LH rear shocks:

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    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:38 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  7. #7
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Sep 2003
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    Remove the Swingarm Pivot Lock Nuts from each side of the swingarm:

    Name:  rod6.jpg
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    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:38 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  8. #8
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Sep 2003
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    Loosen the allen key swingarm pivot bolts:

    Name:  rod7.jpg
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    Last edited by Steve / AF1 Racing; 11-04-2016 at 01:36 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  9. #9
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Note that there is a crucial sandwich washer on the RH side:

    Name:  rod8.jpg
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    Last edited by Steve / AF1 Racing; 11-04-2016 at 01:39 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  10. #10
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Sep 2003
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    Once each pivot bolt has been removed, pull back the swingarm just far enough to remove the Clutch Engagement arm. (This dis-engages the drive shaft)

    Remove the clutch actuator arm and remove the cable from its end. (Note the return spring!):

    Click image for larger version. 

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    Last edited by Steve / AF1 Racing; 11-04-2016 at 01:50 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  11. #11
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Sep 2003
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    Remove the clutch pushrod and bushing (This step can be challenging, because the worn bushing can become stuck in the bore. Needlenose pliers with sharp teeth are useful here):

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Views: 396
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    Last edited by Steve / AF1 Racing; 11-04-2016 at 01:52 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  12. #12
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Sep 2003
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    Clean the clutch pushrod bore and install the new rod, bushing, bearing and outer bushing assembly as laid out below:

    (Note: the pushrod assembly only inserts fully in one orientation. Since installation is blind, patience is key here. DO NOT FORCE IT)

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    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:39 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  13. #13
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Sep 2003
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    Re-install the clutch engagement arm, clutch cable (not visible) and be sure to correctly seat the return spring:

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    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:01 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  14. #14
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Sep 2003
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    Slide the swingarm forward, and re-insert the driveshaft into the engine. Aligning the driveshaft splines is challenging and requires patience. If you are having a hard time aligning it, walk away for a bit, and try again, the alignment is as much witchcraft as it is skill. Once aligned, the swingarm will slide on with very little force. (You know you've got it when the hose clamp retained bellows easily reaches back onto the transmission housing and the swingarm pivot hole lines up with the corresponding hole in the frame):

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    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:41 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

  15. #15
    Racing SERVICE Competition Steve / AF1 Racing's Avatar
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    Reinsert the swingarm pivot bolts, starting with the RH side (remember to put back in the sandwich washer), tighten until the pilot tip of the pivot bolt is engaging the pivot bearing in the frame. (Do not Torque down the swingarm pivot bolt yet):

    Name:  rod14.jpg
Views: 392
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    Last edited by Steve / AF1 Racing; 11-04-2016 at 02:41 PM.
    AF1 Racing, inc / ApriliaForum.com
    9900 North Interstate 35
    Austin, Texas 78753
    direct:512-459-3966 fax:512-482-8319

    Currently:
    '97 RS125 Two Stroke

    Previously:
    '00.5 Mille & '97 RS250.

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