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Re: I have a leaking clutch cylinder just above te
Rebuild kits are available for the clutch slave cylinder from www.cademaster.com under cavalcade parts. You will have to remove the secondary and rear wheel to do this job. While you are there you should fit the "Tracy" plug in the secondary. If it is too much for you, there is an emial group that can talk you through the steps required or there may even be someone nearby that can help. Join the group via www.suzukicavalcade.com
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Purchase a replacement seal kit at your local motorcycle parts store. You will also need to buy or borrow a pair of "circlip" pliers to disassemble and reassemble the slave cylinder (to remove and reinstall the retaining clip inside the cylinder). Make sure everything is SPOTLESS, and I mean surgically spotless, before installing new seals and reassembling. DO NOT use any tools to get the new seals on the piston, just your fingers, or you will be doing the job again soon. Soaking the new seals in clean brake fluid for a few hours before reassembly makes the job easier. It also helps to bench-bleed the slave cylinder before re-installing to make it easier to bleed when you get it back on the bike. The "circlip" pliers come in various shapes and sizes, but something basic like this should do just fine.
I dont recall that there are any orings in the head area. Large leak from head area is caused by cylinder not retracting and seating against headvave. Small leak is usually gaskets between headvalve or cracked tube above headvale or rubber tube seal not seating against body of the gun. Test cylinder movement. Remove the head and push down cylinder, the cylinder should retract. If the cylinder is already down, pull it up. If the cylinder is very hard to pull up, most likely orings too tight or body of gun is warped. If the cylinder moves up with just little force, reinstall head and retest. If small leak, remove head and remove headvalve and look very closely for cracks in the head and tubes.
Clutch slave cylinder rebuilds require the removal of the "secondary" drive unit, the right angle drive unit beside/aft of the left drivers foot peg. While you are in there, you need to check/fit the "Tracy Plug" and check for play in the output bearing.
Parts and detailed instructions are available at www.cademaster.com and if you haven't already done so, join the worldwide yahoo email group with over 1400 members via www.suzukicavalcade.com and ask more questions about this task.
may have a large leak in the slave cylinder. do you see fluid dripping underneath te transmission housing? it could have an internal leak but not as common. check the fluid level in the little reservour on the firewall.
Hi, the likely problem is air in the hydraulic clutch line. This happens when there is a leak in the system that draws down fluid in the reservoir until air is drawn in. You must repair the leak and bleed the system to restore pedal pressure. The leak is usually in the slave cylinder at the transmission, but may also occur in the master cylinder above the pedal. If you can find your leak, I can provide repair instructions--just let me know.
Did you replace the clutch springs with the original ones? or with Barnett ones? the latter are much stronger and will not slip, unlike the original ones. Barnett ones are available from www.cademaster.com under cavalcade parts.
clutch master cylinder is located drivers side firewall,right next to brake master cylinder. it has small shot glass size fluid resevoir mounted above it,fluid is fed through hose down into clutch master. clutch master cylinder has a rod mounter on ft of it that goes through firewall and attaches to clutch pedal under dash . clutch slave cylinder is mounted on ft passenger side of transmission assy. most common leak is from master cylinder,you would be able to look under dash ,follow clutch pedal up to where it attatched to clutch master pushrod.follow that rod to wear it meets up to a small 1 1/2" or so rubber boot.fluid will be leaking from that boot if master is leaking.
the 900 uses the same reservoir for both brake and clutch; it's in front of the firewall on the side of the pedals, immediately visible when you open the hood. Milky plastic, with a screw top; max and min levels marked by lines.
clutch leaks can be at the slave cylinder in the clutch, which will likely cause slipping clutch; at the master cylinder, which may show as fluid inside the car; or in line between them (runs from master cylinder at firewall to front of engine, where the clutch is located).
Look for leaks on ground and relate to location above leak in engine bay