[Okinawa Joe]

So the other day I was riding my 2020 SAS and at a stop light with the bike in gear the bike started to engage clutch and bike started moving I pulled over and let bike stall out. Releasing clutch lever it did not return to normal position. Upon pumping clutch lever multiple times feel and function returned. Unfortunately , f you held the clutch for more than 5 seconds it would bleed of system pressure and clutch would start engaging.

Rode it home luckily 3 miles away. I did not even think. Went on line found an Oberon Clutch Slave and installed it today. It is pretty but unfortunately it did not solve the problem same exact issue. FYI, I bought the bike in 2020 new and have not flushed the brake or clutch fluids. My assumption, based upon observations is that the seals at the clutch master cylinder plunger have been compromised and are leaking between the plunger seals.

I would call local KTM dealers but they will be closed tomorrow and I need a master cylinder rebuild kit. I have searched on line but other than someone in Croatia selling 9me on ebay for $99 plus $32 shipping no joy. Any ideas here. I am suppose to do a week long riding get away with a buddy of mine. We are going to trailer down the Bristol TN are get a B&B and just ride as many roads as we can for 4 days.

If I can't repairing by next Monday 13th itis not a big deal really as my other bike is a 2022 1290 SDR EVO. I would have to suffer and take that. The SAS is just a much more comfortable all day riding machine for multiple days on end as I am 6'5" 270 lbs.

Any hoot I can do the rebuild without much problem. It's just getting parts. Any ideas?

How about disassembling it and cleaning it in clean DOT4? Sometimes accumulated goop can cause the piston to not seal. Brakefluid normally attracts water vapor which creates sludge. I have a 2019 SAR, I just flushed mine before my road trip in Tennessee, worked beautiful. Unfortunately I could not foresee my fuel pump failing. My vacation budget went to a rental truck! LoL

 

[Okinawa Joe]

As I disassembled it already , cleaning the master cylinder lining and reassembly works like a charm. This motivated me to flush the brake lines as well. Used DOT 5.1 . As for the fuel pump, when the bikes get to 18,000 miles or five years I rebuild the fuel pumps. Did this on my RC8R. To many stories of this exact situation

Ironically, my 1290 SAR is my first European bike, always rode Japanese, never an issue. The offending pump, Keihin, WTF? LOL
I will keep an eBay $40 pump unit along with my tools when I travel. Still can't wrap my head around this, replacing pumps before they fail!

 

[Okinawa Joe]

When it happens in your garage it’s on your terms. You have all the tools, a bike lift possibly and you plan it around the tank being mostly empty. It takes little time maybe 2 hours, and your done. When it goes on the road. Not good, minimal tools, flat ground , lifts, etc etc. it’s not racing on some ridiculous incline. A lot of **** can go sideways quick. I know at some point it is just a matter of time. One to be avoided with a relatively small investment that can pay big dividends.

Piece of cake at home, I still have everything from my MC shop, still do work here and there in retirement. Actually with the fuel shutoffs pump replacement in the field isn't bad, it's a simple affair on the KTM.
Rottweiler kit, $140. lifetime warranty, no brainer.