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Thread: Replaced the Clutch Diaphragm and an oil change

  1. #1
    apriliaforum Junkie NorCal_RSVR's Avatar
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    Replaced the Clutch Diaphragm and did an oil change

    For month or so now I've noticed the Mille has had a slight tinge of Blue smoke out the rear. I've read numerous postings from various forums and decided to do the usual suspect (Diaphragm).

    As ive only had the Mille since last year and I dont know the true maintenance of the bike and the Aprilia dealer I bought it from did not know either. I've been going through it entirely for my piece of mind when I noticed the smoke

    With that, since the oil level is fine and there is no oil inside the air box from over filling and then being sucked in I decided to go after the diaphragm.

    With my part number in hand, I called a local dealer and placed the order.
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    $96 later and nearly three weeks wait time, the parts arrived. I planned for this weekend to open the Mille up as it was going to rain and what a great time to do so.

    Upon removing the cover I immediately noticed there was oil on the case side and in the vacuum line. I cleaned all of the oil up and even cleaned up the inside of the cases outer edge for a better seal and then went into removing the lock nut from the hex end of the clutch push rod.
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    Diaphragm and backing plate exposed. I anticipated the backing plate to easily come off of the rod/diaphragm but was surprised to find that it was quite stuck together. The pressure plate,diaphragm and backing plate came off as one piece and it took some effort to separate them from each other. You can see by the pictures that they were mated together for quite some time with matching residue patterns on each item.
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    Pressure plate/Diaphragm
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    Center of old diaphragm
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    New and old diaphragms side by side. You can clearly see the difference in the center hole locations. Upon inspection the center hole of the diaphragm was ovaled and rough around the inner edge. Additionally, I found a small 2mm or so slit near the bottom of the diaphragm just an inch from the outer edge.
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    Afterwards, I merely worked backwards in replacing all the parts. (Washer, backing plate, diaphragm, pressure plate, washer, lock nut.)
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    Last edited by NorCal_RSVR; 03-21-2016 at 08:19 PM.

  2. #2
    apriliaforum Junkie NorCal_RSVR's Avatar
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    With the bike having been opened up and oil being sucked through the diaphragm and into the vacuum line, I went and did an oil change along with a new K&N 152 oil filter and Motul 3000.
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    After setting the oil level correctly, I put her all back together. Now she just needs a nice bath (wheels are dirty).

    Upon initial start up, there was a little bit of burn off but then she settled right in. I dont see the light blue smoke in the exhaust but I will monitor it and provide updates. Im certain the slit in the diaphragm was the culprit as oil was all over the inside of the casing

    So thanks to this forum and all of the great insight from other threads/posts, the issue seems fixed

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    Last edited by NorCal_RSVR; 03-21-2016 at 02:14 PM.

  3. #3
    apriliaforum expert spesnaz's Avatar
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    She's beautiful! I love the lines of the first gen milles!

    Sure feels good when you find confirmation of the issue, doesn't it? Doesn't take much damage for vacuum to pull oil through.

    Bob

  4. #4
    apriliaforum Junkie NorCal_RSVR's Avatar
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    Quote Originally Posted by spesnaz View Post
    She's beautiful! I love the lines of the first gen milles!

    Sure feels good when you find confirmation of the issue, doesn't it? Doesn't take much damage for vacuum to pull oil through.

    Bob
    Thanks Bob. Yeah the gen1 Mille R's are incredible and I like them over everything else, well minus the RSV4 RF

    A mere simple fix sure made a huge difference.

    Now that's she's ready to roll, who's going to Laguna Seca for WSBK in July?
    Last edited by NorCal_RSVR; 03-22-2016 at 12:23 AM.

  5. #5
    apriliaforum expert J.R. Bob Dobbs's Avatar
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    Beautiful bike and nice write-up. Now throw out some of the crap in your garage! I'd start with the pink bins
    Jap bikes suck.

  6. #6
    apriliaforum expert CRMNL's Avatar
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    good post.
    hubris-that's the game with the blocks, right?

    /ˌʌɪəˈtɒlə/

  7. #7
    apriliaforum Junkie NorCal_RSVR's Avatar
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    Quote Originally Posted by J.R. Bob Dobbs View Post
    Beautiful bike and nice write-up. Now throw out some of the crap in your garage! I'd start with the pink bins
    Thank you!

    Yeah Id say it comes from having a wife who holds on to everything and having three kids. And to think I just got rid of and sold a bunch of stuff too. But we have both cars, four motorcycles, bikes and all kinds of other stuff so not too bad I think.

    Believe me, I'm not fond of the pink bins. You didn't see the other 15 or so on the other side of the garage wall, lol.

  8. #8
    apriliaforum expert cew's Avatar
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    Nice write-up.

    Isn't that diaphragm part of the 'slipper clutch'? Did you notice any difference in feel (or running) between the old damaged one and the new one?

  9. #9
    apriliaforum Junkie NorCal_RSVR's Avatar
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    Quote Originally Posted by cew View Post
    Nice write-up.

    Isn't that diaphragm part of the 'slipper clutch'? Did you notice any difference in feel (or running) between the old damaged one and the new one?
    You're correct, it's part of the vacuum assisted slipper clutch.

    As far as feel, I haven't noticed a difference by replacing the diaphragm in itself (though lever pull is much nicer now and im not sure it's attributed to the diaphragm, though possible)

    But I did notice a difference in the smoothness of shifting and finding "N" with the 20W-50 I put in the bike during the oil change. Im also thinking about changing out the oil jet for the later model 40 i believe.

    I rode to work today and not only did she feel great (shifting) plus there was no smoke screen effect anymore either
    Last edited by NorCal_RSVR; 05-25-2016 at 02:23 PM.

  10. #10
    apriliaforum Junkie NorCal_RSVR's Avatar
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    Update: I'd like to report that the blue smoke experienced some time ago has absolutely been fixed with the parts replacement I did on the diaphragm. I just went on a 120mi loop yesterday and I reviewed the GoPro footage and there was nothing.

    Once again thank you AF1 for providing an incredible forum for collective minds to come together and share ideas and for those of you who make the contributions!
    JP

  11. #11
    apriliaforum Junkie Six5's Avatar
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    Thanks NorCal_RSVR for the nice step-by-step and good photos!


  12. #12
    apriliaforum Junkie NorCal_RSVR's Avatar
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    No problem, glad to help in any way. I don't think I've seen someone do one of those before and I thought, well I've got my phone next to me might as well snap some pictures

  13. #13
    apriliaforum expert SoulDaddy's Avatar
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    This thread isn't too old to resurrect, so here goes.

    I had a slow, small oil drip from beneath the clutch slave so I suspected the push rod seal was bad and replaced it. Now the clutch will not disengage and the lever won't travel its normal full distance. During the repair I removed the clutch cover and pressure plate to pull the rod. It looked ok but I used some fine steel wool to dress it up a bit and reinstalled it with a light coat of silicone grease. The pressure plate, diaphragm and clutch cover went back in well enough as did the slave but obviously something on one end or the other of that rod isn't happy.

    I'll open it all back up but thought I'd also check with the think tank to see what y'all had to say. Not the merriest Christmas Eve I can think of but if I can get a ride in tomorrow morning that'll be just fine.


  14. #14
    apriliaforum Member Belden's Avatar
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    I would like to add this:

    The clutch diaphragm can be purchased easily by 1/10 of the aprilia price.

    Just google athena 407185 and youll find plenty of options.

    For example this german provider: https://www.mvh-shop.de/Clutch-cover-gasket_230

    I've used the same part myself for a couple of years without any issues.
    2000 RSV Mille (R-ish)
    -Öhlins radial front
    -Öhlins rear shock
    -O.Z Wheels
    -Arrow exhaust
    -Collectormod

  15. #15
    apriliaforum expert
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    Pretty hard to find here. Doesn't show up on Google.
    Don-M

    2003 Aprilia Tuono
    2009 Moto Guzzi Griso 8V Sold it
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