[Grizz]

No worries. I conferred with a friend of mine who was a master mechanic in his early years. I his opinion sympt9ms are synonymous with a failure of the seal in master cylinder. Clutch master is a Magura 167 12mm DOT assembly. Finding a rebuilding was a challeng. Everything was a mineral rated rebuild kit. This morning I finally found a 167 12mm DOT rebuild kit. TripleClampMoto.com , located in Canada I believe.any hoot $66 delivered , using DHL Express. ($48 +$18 shipping) So know I will go about breaking it down.

 

[Grizz]

Any hoot, good news. I disassembled the main cylinder and I examined the seals on the plunger. Put them under a magnifying glass , they looked virgin . No scratches, blemishes or small tears. So something else must be a foot. I point my light down the bore of the clutch master cylinder and on the walls was a gray covering of what appeared to be deposited aluminum oxide.

So I got a shop microfiber rag soaked the end of it a proceeded to twist it to clean the cylinder walls. Did it fore roughly a minutes and pulled it out. There was a black residue on the cloth. Did the same to the seals on the plunger put some DOT 5.1 on it to lubricate it and place it back in the cylinder . Placed the plastic snap ring in, and the the plunger pin and rubber boot. Reassembled the clutch lever and the system was ready to prime .

I had emptied the clutch lines as I wanted to get rid of all the old fluid in the line. Then I reversed bled the line from the clutch slave bleeder valve. After the clutch reservoir was filled I put on the cap, raised the line completely vertical and pumped the clutch lever 10 times. Tryin to make sure Al the air was out of the system. I secured the assembly to the bar and I was ready to test.

I held the lever closed for a minute and released it. It felt good. So I decided it was time to take the bike for a ride. Took it through downtown Annapolis a lot of stop and go. The feel of the clutch was a lot better than stock, very smooth and progressive engagement of the clutch, which stock could be snatchy. absolutely no loss of pressure in the system, when holding the clutch. I canceled the order Triple clamp moto for the rebuild kit . Magura USA say they estimate between 60,000 to 80,000 miles before rebuild. I am at 12,000 miles.

I think what happened is contaminants built up in the system and the aluminum oxide coated the wall to the point that it would not hold pressure. Lesson to be learned? Flush the brake and clutch lines every two years per maintenance schedule. I’ll be flushing brake lines this week. I ordered a larger can of DOT 5.1 fluid.

Sorry about no pics wasn’t thinking. It was a maybe 4 of 10 on the level of difficulty. I went on line a got a video of doing a rebuild of a Magura 167 clutch master cylinder. It was pretty much spot on.

 

[Grizz]

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

I have had similar experiences

 

[Grizz]

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

 

[Grizz]

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!

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.