Clutch setup problems

[flowmaster]

Hi all

I cant get my clutch to release.I've rebuilt the entire bike(not the engine and clutch.I got a replacement engine from Motorworks for my terrible looking paint corrosion) and am having trouble getting the clutch to release.I've replaced the copper washers and bled the system in the normal way.I've got pressure nearly all the way on my lever(or what feels like pressure) but the clutch doesn't release.There are still tiny bubbles floating up from the bottom of the reservoir but none come out the slave end when I bleed it.Is it the master cylinder?It was sat in a box for a good 6 months before going back on the bike.Seals knackered?Shouldn't I get any dissengagement of the clutch even if the master cylinder seal is not up to scratch.I'm also using a red vitam fluid from motorworks which they say is for clutches.Do I need to use the proper V10 fluid.

Is the clutch push rod the same size from my GS04 to a GSA 07

many thanks

 

[Tomcat]

I needed to have some work done on the clutch of my '04 GS (the plate was sticking on the splines, so not releasing cleanly) and whilst the bike was apart I asked for the pressure plate to be replaced. The work was done by an independent BM mechanic (Brian Giles in Tunbridge) who explained that there had been a redesign of the clutch pressure plate and release mechanism post '04. He fitted the later pressure plate only (not the modded release mechanism). The clutch is fine but it bites towards the end of lever travel.

So it looks as though there have been changes to the clutch between 04 and 07, although I don't know the full details. Your best bet would be to talk to a BM mechanic.

 

[st247]

Looking at Realoem the clutch pushrod has changed part numbers. When you say bled in the normal way do you mean like this-

 

[flowmaster]

Thanks Tomcat,sounds interesting.When I got the engine from motorworks I thought about putting my original complete clutch unit on it but gambled on the one that was on it already.It had done about 16000 miles whereas mine had done 20000.Maybe that gamble hasn't paid off ! I think your right I need to find out if the 2 are compatible.
ST247..I'll have a look at the pushrods on the parts list also no I bled it like brakes from the clutch lever not like the drawing,might be where I'm going wrong.How can you inject fluid into the slave from the valve won't it cause an air lock.I followed the haynes manual procedure for bleeding the system which shows conventional bleeding techniques.

 

[flowmaster]

Just seen the difference in part numbers for the pushrod.The earlier clutch pushrod from 03/04 is described as conical and the later pushrod for my 02/07 clutch is described as spherical.Lets hope theres an easy fix for this.

Thanks fellas

 

[st247]

ST247..I'll have a look at the pushrods on the parts list also no I bled it like brakes from the clutch lever not like the drawing,might be where I'm going wrong.How can you inject fluid into the slave from the valve won't it cause an air lock.I followed the haynes manual procedure for bleeding the system which shows conventional bleeding techniques.

Not had to bleed mine, but i've bled other hydraulic systems like this before and it works fine. With a bit of luck clearing all the air out will solve the problem. Good luck.

 

[flowmaster]

when you say you've bled others in the past and it works fine do you mean by the conventional way or by injecting the fluid into the slave cylinder as in the diagrams

 

[st247]

when you say you've bled others in the past and it works fine do you mean by the conventional way or by injecting the fluid into the slave cylinder as in the diagrams

I've bled systems by forcing (injecting) the fluid into the slave cylinder and back to the master cylinder. The idea is that any air rise with the fluid to the master cylinder and is expelled. It may be that bleeding the other way will work equally aswell, but it's worth a try if you've not got any other possibilities before you start to strip the box off again.

 

[Kremmen]

Clearing trapped air from servos/slaves & master cylinders has been a known problem for some time now.... reverse bleeding using a syringe or pressure bleeding with air is the norm ....... and even when using the above methods you can still have trapped wind.... where did that smell come from

 

[flowmaster]

Thanks for your help everyone.I've decided to order the later pushrod with the spherical end not the conical end.We'll see what happens.