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Old 01-15-2012, 06:35 PM   #1 (permalink)
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Default clutch re-build? 2003 250 EXC

Clutch fluid leaked out while riding. Anyone have any luck re-building the clutch?

Jim
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Old 01-16-2012, 06:02 PM   #2 (permalink)
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Jim,

Do you mean the slave cylinder?

It's usually the o-ring #67 if so.

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Old 01-16-2012, 07:46 PM   #3 (permalink)
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Default clutch rebuild

hi bajadog!!!!yes probably slave cylinder but they dont sell just o-ring i heard must buy rebuild kit $150 including bleeder kit/oil
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Old 04-10-2012, 03:06 AM   #4 (permalink)
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I don't know the bike but those hydraulic systems are pretty simple "usually". One pump at the lever, a hose and then the actuator. So, if you've added fluid to the system and it still comes up empty, then you've most likely got a leak. If the whole system is external then it wont hurt to try to bleed it again though. I'm guessing the vacuum system you used actually helped drain your clutch, so I might suggest just trying the old way of bleeding it. (This is all based on the thought that your set up is anything like I will describe)

Run a length of hose from the bleed nipple on your actuator (I'm guessing it's down near the clutch plates...should be anyhow) to a jar on the ground filled with enough fluid that the end of the hose sits in it, not drawing air. Then pop the top off the clutch lever master cylinder on the bars, add a little fluid and squeeze the lever until the fluid is taken up OR you feel pressure building at the lever. Feeling pressure build up at the lever is the ultimate goal. It can take a bit for enough fluid to be taken up but just keep adding it until you notice a definite leak or the pressure build. (If it's a leak, then you've seals to replace.) Once you feel pressure at the lever, give it a firm squeeze, and open the bleed nipple at the actuator. The lever will come back to the bar, a little fluid will come out the hose...almost immediately close the bleed nipple again. Then repeat the whole affair, adding fluid, pumping the lever until it comes up to pressure (Note: the more the system comes up to full, the slower you should squeeze the lever as it can shoot fluid pretty far after a while.)

Anyhow, if you stick to that, after a while, the lever will come up to pressure quickly, AND the fluid that comes out of the bleed nipple will have fewer and fewer bubbles in it. When it runs clean, you'll be golden.
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