I just removed the front sprocket cover to count the teeth on the front sprocket (it's 15). I did not follow the recommendation in the manual to pull in the clutch level and tie it back to the handgrip. It says that will prevent the piston front comming out of the seal (I think-I don't have the manual in front of me). But it all sounded counter intuitive so I didn't do it. Now the clutch will not fully release. There is a little bit of release but not enough for the bike to be rideable. There has been no problem with the clutch prior to this.
What happened and how do I fix it?
Thanks in advance for any help.
John

 

Simply bleed the clutch - viola

Hose, jamjar, 8mm ring spanner, recommended hydraulic fluid.

Keep on topping the reservoir as it has a small capacity and you don't want to introduce anymore air. If you can get a large syringe then you can suck from the slave, again remembering to keep the reservoir topped up. Did I mention keeping the reservoir topped up...

 

Yeah, it's a PITA with the clutch. There's only the clutch spring pressure pushing the fluid out. You have to squeeze, open, shut pretty quickly and in rapid succession. All the air will eventually come out.

 

Really, that's all it is, just air in the line? OK Thanks, then I will go ahead and bleed the system. It's a pain in the ***, but I can do it just need some patience.
But.. how the hell did it get in there? Isn't it a closed system? Is the seal created by the clutch engagment rod. Probably a dumb question but I'm just curious.

 

Well because the piston extends in the slave cylinder, when you remove it due to the spring inside.

This causes air to get sucked into the master cylinder because the lever is all the way out.

This is why they tell you to tie the lever to the bar when you remove it.

 

Ahh, so the air enters at the master cylinder! Ok next question, Why does holding the level in prevent air from entering at the master cylinder? I now have the maual in front of me, is it because the piston at the master cylinder has now closed from the reservoir so that no air (if the level is low enough) could possibly get in? It would have to, how else could it create pressure. I think I answered my question. Am I correct?
Thanks again.

 

Yep, you sure did.

 

Bled the clutch today and everything is hunky dory! Thanks Guys.

 

Maybe a little late on this but a Mighty Vac makes this really easy.

 

:-)