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Clutch fluid leak?

5K views 6 replies 3 participants last post by  beastman487 
#1 ·
I'm sure it's been covered before. My clutch lever pull got very light and will no longer fully disengage. Fluid in master reservoir was "low" so I topped up. While open, I tried to gently pump the lever to check for air bubbles, nothing. Down low at the release cylinder there appears to be a leak (photo).

I changed my chain and sprockets in 2009 following the webbikeworld guide and using the haynes manual. I followed it exactly and have been safely riding it with no issues until yesterday. I have not changed the clutch fluid, even when I did the sprockets. It's murky.

I'm planning on bleeding and replacing the fluid, but I want to be sure I get the seals I need to eliminate this problem/leak from recurring. The article here recommends replacing the clutch pushrod, is that necessary? Parts weren't hard to find then, are they now?
 

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#2 · (Edited)
It looks like the slave cylinder has developed a leak. Air is getting into the system, which accounts for the problems with the clutch release and lever feel. At the least, you need to replace the seals.

The fluid should be changed every 3 years or so, in order to get the maximum life from the system. Brake fluid is hygroscopic and this leads to corrosion in the housings. At this point, replacing the slave with a new part might be your best bet.

Don't waste your time replacing the fluid at this point, unless you repair the leakage, but, also, don't allow the old fluid into any new or repaired slave cylinder.
 
#3 ·
If I understand correctly from several threads on here, the biggest issue with successfully changing the pushrod and its OIL seal is that the seal is very fussy and delicate. If there is the slightest imperfection on the pushrod, you stand a good chance of still having oil leakage. So some advocate using a new pushrod.

If you can determine for certain that your leak is brake fluid and not oil, your best bet may be to just rebuild or replace the slave cylinder and disturb the pushrod/seal as little as possible. If it is actually oil, then read up on the various "clutch pushrod oil leak" threads.
 
#6 ·
Best way I can think of to tell which it is is by fluid level. It's too small a leak to be able to tell with oil level, but since the clutch fluid has such a small volume, any leak there should be easily detected by low clutch fluid level.

I haven't had my slave apart, so can't advise on that.
 
#7 ·
Being as impatient as I am, I couldn't wait for new parts to ship. I flushed out the old fluid. I took the slave assembly off and apart. Cleaned it all up. Bled in new fluid, by myself, totally possible with a strong rubber band to hold the lever to the bar while bleeding the valve. It was not leaking oil from the pushrod seal. The old fluid was junk. With new fluid the clutch action was smooth and solid. Shifting perfectly. I will probably still swap out the seals and cylinder at some point.
 
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