Clutch Master Cylinder
Clutch Master Cylinder Removal
-Remove the clamp bolts and clamp, and t.ake the clutch
master cylinder off the handlebar.
Clu tch Master Cylinder Installation Notes
-The master cylinder clamp must be installed wilh the
UP mtlrk faced upwards.
-Tighten the upper clamp boll first, and then t.he lower
clamp bolt to the specified torque (see Exploded View).
There will be a gap at the lower part of the clamp after
A. Tighten upper clamp
B. UP Mark
Clutch Master Cylinder Disassembly
-Orian the clutch fluid.
-Pull b£lCk the dust cover, and remove the banjo bolt
disconnect [he clutch hose from the masler cylinder.
There i-. a flat washer on each side of the hose fitting.
_Remove the clutch lever Jnd the master cylinder.
-Remove the push rod, the dust seal and the circlip.
Master Cylinder Inside Parts
Rod Round End
3. Dust Seal
6. Piston Assembly
7. Secondary Cup
000 not remove the secondary cup from the piston since
removal will damage it.
Clutch Master Cylinder Assembly Notes
-Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.
oUse only disc brake fluid, isopropyl alcohol, or ethyl
alcohol, for cleaning parts. Do not use any other fluid
for cleaning these parts. Gasoline, motor oil, or any
other petroleum distillate will cause deterioration of
the rubber parts.
Oil spilled on any part will be
difficult to wash off completely, and will eventually
deteriorate the rubber used in the cylinder.
_Apply brake fluid
the parts removed and to the
inner wall of the cylinder. Take care not to scratch the
piston or the inner wall of cylinder.
_Check to see thai the piston return spring pushes back
the piston to its rest position when the spring is
-Install the push rod with the dust seal fitted into the
cThe push rod round end must be faced inwards.
-Use a new fl.lt washer on each side of the hose fitting.
-Tighten the banjo bolt to the specified torque (see
_Fill the clutch fluid into the clutch line dnd bleed the
clutch Itne (see Clutch Fluid Changing and Clutch Line
Clutch Master Cylinder Inspection
-Check tha.I there are no scratches, rust or pitting on
the master cylinder and on
*If the master cylinder or piston
_I nspect the primary cu p
*If a cup is worn, dam aged, softened (rotted), or swollen,
*If fluid leakage is noted at the clutch lever, the piston
assembly should be replaced
renew the cup.
-Check the dust cover for damage.
*If it is damaged, replace It.
_Check that the relief and
*If the small rel ief port
plugged, the clutch will
slip. Blow the ports clean with compressed air.
-Check the piston return spring for any damage.
*If the spring is damaged, replJce it.