Hi thx for the add. Hi guys I'm a motorcycle mechanic in Atlanta ga and im having trouble with the clutch on the bike. The guys a new rider but after riding it i assumed the slipping when accelerating meant it just needed new friction plates and problem solved. I now have a problem with the clutch not engaging to shift into gear. I rebuilt the master cylinder new, new dot 4, bled to the slave cylinder and sealed it up and still nothing. I noticed with the slave cylinder in hand with thumb over cylinder, that when i squeezed the lever it barely pushed my thumb out. The only thing I haven't rebuilt is the slave cylinder. I replaced the 2 O ring spring plates and holder. I also replaced the spring plate with the groove cut outs in it that don't limlne up with any gear. I did notice of the 2005 models they added in a bezel that fit into those groves to cause less wear and tear. Should I order the bezel with grooves too? Somebody help!!

 

Ok I have replaced the master cylinder and cleaned the slave cylinder real well and also put new crush washers on the hoses. I still can't get the clutch to disengage when I pull the clutch lever. What is the problem?

 

From what I've read it does sound like the Hydraulic side as apposed to the Clutch components are the issue.
You "Replaced" the Master, With New OEM or used ?
Are you using the original Hose ?

 

I rebuilt the master with a new rebuild kit from K & L and replaced the 4 washers on the brake hose which appears to be the original hose yes.

​​​​​So after fiddling around with it, it seemed as if the plunger was not pushing the master cylinder in far enough to replace the pressure in the resovior so i tried putting a rod a few mm's longer in place of the OEM and it seemed to help but it needed to be pressed on a little further and this is when i put a washer in between the lever adjuster setting **** and the hinging pivot point and just the added 2mm from the washer made the lever hard to pull but when pulled all the way in I was able to fully disengage the clutch and it rolled forward. I couldn't leave it rigged for the customer but had to and just informed him that he needs to replace the lever with one less worn preferably an OEM lever. What are your inputs on that? Is there something im overlooking? I could possibly make a video to describe what I did if my wording may have been a bit confusing. Again thanks for your help.