Hydraulic clutch control

2 -	Hydraulic clutch control

1	Clutch master cylinder

2	Inspection plug (replacement part)

3	Lever pivot pin

4	Lever with grub screw

5	Fluid reservoir cover

6	Clutch hose

7	Mounting clamp

8	Sealing washer

9	Rubber mounting

10	Banjo bolt

11	Bleed valve

12

13

14	Clutch slave cylinder

15

16	Clutch pushrod

17

18	Microswitch

Parts catalogue


CLUTCH CONTROL

Important

Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.

Removal of the clutch master cylinder assembly

Warning

The clutch master cylinder manufacturer advises against servicing of the clutch master cylinder (1) due to the safety-critical nature of this component. Incorrect overhaul of this component could endanger rider safety.

Maintenance operations of the master cylinder are limited to replacing the following parts: control lever, reservoir unit, and master cylinder fasteners.


Operation	Section reference
Drain the clutch system	D 4, Draining the clutch hydraulic circuit
Remove the LH hand guard-mirror assembly	E 1, Removal of the hand guards - rearview mirrors

Remove the dust cap (12) and the bleed valve (11) and unscrew the banjo bolt (10) and remove the hose (6), taking care to recover the sealing washers (8).

Unscrew the two clamp bolts (7) securing the clutch master cylinder assembly to the handlebar.

Remove the clutch master cylinder assembly (1). to dismantle the assembly, refer to the exploded view diagram at the beginning of the chapter.

Refitting the clutch master cylinder assembly

Tighten the retaining screws (7) to the specified torque (Sect. C 3, Frame torque settings), in the sequence 1-2-1, starting with the uppermost screw.

Locate the hose (6) on the slave cylinder (14), ensuring that the hose end fitting is correctly positioned relative to the slave cylinder (14).

Warning

An incorrectly positioned hose can cause clutch faults and interfere with moving parts.

Locate the two sealing washers (8) and tighten the banjo bolt (10) to the specified torque (Sect. C 3, Frame torque settings).

Refit the bleed valve (11) and the dust cap (12).

For the positioning of the clutch hose (6) and retaining clips, see the illustration at the end of this section.


Operation	Section reference
Fill the clutch circuit	D 4, Filling the clutch circuit
Refit the LH hand guard-mirror assembly	E 1, Refitting the hand guards - rearview mirrors

Removal of the clutch slave cylinder

Warning

The clutch slave cylinder manufacturer advises against servicing of internal components of clutch slave cylinder (23). Incorrect overhaul of this component could endanger rider safety.

Only the following parts may be replaced: the bleed valve, the seal and the complete pushrod assembly.


Operation	Section reference
Drain the clutch system	D 4, Draining the clutch hydraulic circuit

Undo the three bolts (15) securing the clutch slave cylinder (14) to the engine and withdraw the unit from the crankcase.

Remove the dust cap (12) and the bleed valve (11) and unscrew the banjo bolt (10), taking care to recover the sealing washers (8): the unit (14) is now disconnected from hose (6).

Push in the piston to force out all the fluid from inside the cap.

At this point the clutch pushrod (16) may also be withdrawn. Check the state of wear of the two O-rings (17) and renew them if necessary.

Notes

If the two O-rings (17) are renewed, it will also be necessary to renew the O-ring (13) of the clutch slave cylinder (14).

Refitting the clutch slave cylinder

Notes

If the clutch pushrod (16) is renewed, it will also be necessary to renew the O-rings (17) and (13) of the clutch slave cylinder (14).

Grease and refit the clutch pushrod (16) with the two O-rings (17).

Notes

If the slave cylinder unit (14) is renewed, it will also be necessary to renew the O-ring (13) and the two O-rings (17) of the clutch pushrod (16).

Locate the slave cylinder unit (14) in the crankcase and tighten the bolts (15) to the specified torque (Sect. C 3, Frame torque settings).

Locate the hose (6) on the slave cylinder (14), ensuring that the hose end fitting is correctly positioned relative to the slave cylinder (14).

Warning

An incorrectly positioned hose can cause clutch faults and interfere with moving parts.

Locate the two sealing washers (8) and tighten the banjo bolt (10) to the specified torque (Sect. C 3, Frame torque settings).

Refit the bleed valve (11) and the dust cap (12).

Refer to the diagram on the following page for correct positioning of the retaining clips for the hose (6).


Operation	Section reference
Fill the clutch circuit	D 4, Filling the clutch circuit

Positioning of the clutch hose