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August 20, 2009 at 10:04 am #97034
my clutch on my 05 TE 510 husky wont hold pressure , it stopped working for me last sunday and cut my ride short ,i bleed it and its allright and in 15 min or so its lost all pressure . I have pulled the slave cylinder apart tonight and the O ring looks bit flat edged so im going to get a new one tomorrow and give it a try, has anyone had a similar problem and if so how did you fix yours, theres a place called 7602 racing that has a replacement slave cylinder as well its a bit wider and a quad-ring seal looks the go but thats in america and wont be here intime for the weekend . Tell you how it goes tomorrow. Cheers Ian
August 20, 2009 at 8:33 pm #149242
Anonymousi think lotsa had a similar failure last week.
August 20, 2009 at 9:19 pm #149274champo35 wrote:
Quote:i think lotsa had a similar failure last week.Good tech help Champo, bet he fixed it now :dry:
huskybloke it seems you are onto the cause of your problem, fuild by passing the seal would give you the loss of hydraulic pressure needed to move the slave piston at the clutch cylinder. Was there an external leak as such?
TB
August 20, 2009 at 11:01 pm #149277The magura Clutch setups have a good rep for non-failure, however I do know that sometimes people put the wrong fluid into them and it reacts with the seal materials and causes problems.
My 300s had 200 hours of riding on it and 4 years of sitting and still worked like new, maybe the QA or component quality is dropping a bit.BC
August 21, 2009 at 12:02 am #149293
AnonymousI agree with TB it sounds like it could be a dodgy seal. It woulld explain why the pressure tapers off after a little use. If the oil isn’t visibly leaking though there can’t be too many other things to cause a problem.
August 21, 2009 at 12:53 am #149313One would think it would leak some where if a seal was dicky, unless it was bleeding back into itself up at the handlebar end of the world, do you have to rebleed to get pressure or just pump it up with the lever, if you rebleed and get air out , then where has the fluid gone, Questions , questions and more questions, I dont know if they help or not:)
August 21, 2009 at 8:15 am #149314there is no external leaking at the handlebar endand the oil is going some where got a new o ring for slave cylinder so im goin to have a go at it now tell yas how iwent later
August 21, 2009 at 9:56 am #149385im no tech nut, but from my car fixing days, it sounds like a master cyl problem. if it is the slave, the only place it can go is out! if its not leaking anywhere it must be getting past the master cyl seals and back into the reservoir.
unless ive missed something here, it seems the only logical answer (as mr spock would say:laugh: :laugh: )
the slave is just a piston and only works when it is fed a pressure. its not spring loaded as such, hence why disc brakes rub a little when not in use. its the master that is, if you like, a two way valve since you can squeeze the slave piston back out when replacing pads. if the seals are knackered in the master, it will leak fluid back into the reservoir from the relief port in the piston upon application of the brake. if it can be “pumped up” it can only be two causes, the master is faulty, or has air in the system.
if it can be pupmed up, i would suggest pumping it up and then cable tieing the lever in overnight. if its sloppy in the morning and you have lost no fluid, it must be the master.
thats how it worked when i was at school anyway.
hope i have helped in some way;)
(a rare useful post from the menace):laugh: :laugh:
August 21, 2009 at 11:51 am #149408i think your on the money menace have tried to bleed it with the new oring on the slave cylinder hasnt done a thing , still the same so im going in tomorrow and getting a kit for the resevoir should do the trick i think see how it goes
August 21, 2009 at 12:09 pm #149409menace wrote:
Quote:im no tech nut, but from my car fixing days, it sounds like a master cyl problem. if it is the slave, the only place it can go is out! if its not leaking anywhere it must be getting past the master cyl seals and back into the reservoir.unless ive missed something here, it seems the only logical answer (as mr spock would say:laugh: :laugh: )
the slave is just a piston and only works when it is fed a pressure. its not spring loaded as such, hence why disc brakes rub a little when not in use. its the master that is, if you like, a two way valve since you can squeeze the slave piston back out when replacing pads. if the seals are knackered in the master, it will leak fluid back into the reservoir from the relief port in the piston upon application of the brake. if it can be “pumped up” it can only be two causes, the master is faulty, or has air in the system.
if it can be pupmed up, i would suggest pumping it up and then cable tieing the lever in overnight. if its sloppy in the morning and you have lost no fluid, it must be the master.
thats how it worked when i was at school anyway.
hope i have helped in some way;)
(a rare useful post from the menace):laugh: :laugh:
Well posted Menace! Well thought out, nicely explained and logically constructed. Makes sense to me! That’s why I’m quoting your post! :laugh: :laugh:
August 21, 2009 at 12:50 pm #149477have a good look down the cylinder while you have it apart husky, check for any scoring.
clean it well and when you get to assembling it again, pour some brake fluid over the piston and all the seals and rings. thats what my dad taught me …..he is way old school:laugh: :laugh: :laugh:
August 21, 2009 at 8:19 pm #149481Ian
Mita Blue mentioned that the incorrect fluid could have contributed to this issue, the timing seems about spot on for the fluid to do damage since your rebuild after your ride with me in nundle, could be worth a look,this hurts but I`m thinking menace wins the assistance prize this thread so far.
BoonyAugust 21, 2009 at 10:33 pm #149487My clutch died last Sunday on the trails.
I found my clutch reservoir empty with no external sign of leak. I’m thinking if the slave seal is bypassing slightly into the engine, over a period of time the reservoir will run dry. It happened about four months ago and to fix it I just filled the reservoir ,bled it removing the old fluid and it has worked fine since then.
The correct fluid has been used.
I’ll try the sugestions above also.
Huskybloke
Where did you get the slave piston oring? KTM shops want to sell me a whole piston and slave cylinder.August 22, 2009 at 3:52 am #149491lotsa wrote:
Quote:My clutch died last Sunday on the trails.I found my clutch reservoir empty with no external sign of leak. I’m thinking if the slave seal is bypassing slightly into the engine, over a period of time the reservoir will run dry. It happened about four months ago and to fix it I just filled the reservoir ,bled it removing the old fluid and it has worked fine since then.
The correct fluid has been used.
I’ll try the sugestions above also.
Huskybloke
Where did you get the slave piston oring? KTM shops want to sell me a whole piston and slave cylinder.i think the problem is a bit of both the new oring on the slave cylinder certainly improved the sealing around the slave cylinder but i think the plunger in the resevoir could have been on the way outas well, because after getting the new plunger piston there is no comparison with the old one it was stuffed . Now 2 points lotsa the o ring for the slave cylinder take your old one to a cbc bearing ( or in my case it was a SKF bearings at sandgate newcastle who i cannot say enough about they have helped me heaps)and they will size it up for you and give you a replacement one he ended up just giving me one for nothing. POINT2 now when you are going to replace your magura clutch plunger / piston remember there are quite a few brands that use Magura clutches, when i rang up watsons at cessnock a husky kit for the magura clutch resevoir was $130 for the same thing off a TM dealer around the corner $ 41 bit of a difference EH! it looks a little bit different but it fits and it works. and just on a quick note on SKF bearings when i done the bigend rebuild on the husky mains bearings from the husky dealer $145 each SKF had the same C3 bearing but without the groove for the retaining clips for $8. 50 i then took them to a toolmaker who put them on his lathe and machined the groove in them for mefor $40 so all up it was $57 and there is no difference just make sure you ask for C3 bearings as these have the right tolerences, ive done about 700KM since the rebuild all is sweet. so my advice is get a bit of a relationship between you and your local bearing and seals dealer it will save you heaps . cheers Ian
August 22, 2009 at 12:22 pm #149505huskybloke wrote:
i think the problem is a bit of both the new oring on the slave cylinder certainly improved the sealing around the slave cylinder but i think the plunger in the resevoir could have been on the way outas well, because after getting the new plunger piston there is no comparison with the old one it was stuffed . Now 2 points lotsa the o ring for the slave cylinder take your old one to a cbc bearing ( or in my case it was a SKF bearings at sandgate newcastle who i cannot say enough about they have helped me heaps)and they will size it up for you and give you a replacement one he ended up just giving me one for nothing. POINT2 now when you are going to replace your magura clutch plunger / piston remember there are quite a few brands that use Magura clutches, when i rang up watsons at cessnock a husky kit for the magura clutch resevoir was $130 for the same thing off a TM dealer around the corner $ 41 bit of a difference EH! it looks a little bit different but it fits and it works. and just on a quick note on SKF bearings when i done the bigend rebuild on the husky mains bearings from the husky dealer $145 each SKF had the same C3 bearing but without the groove for the retaining clips for $8. 50 i then took them to a toolmaker who put them on his lathe and machined the groove in them for mefor $40 so all up it was $57 and there is no difference just make sure you ask for C3 bearings as these have the right tolerences, ive done about 700KM since the rebuild all is sweet. so my advice is get a bit of a relationship between you and your local bearing and seals dealer it will save you heaps . cheers Ian[/quote]Thanks Ian
I did just that. The slave piston oring is 24 x 2mm and the clutch is working. A better test on the trails. There are some rub marks on the bore of the slave cylinder but I’ll see how it goes. If the TM dealer around the corner in Cessnock is also the KTM dealer in the main street I’ll get a reservoir plunger from them or a bloke in QLD.Thanks for big end info. I hope I don’t have to use it though.
Happy trails
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