My07 let water in during a river crossing. I instantly emtied water out and bike ran for ten minutes then the stator died! Had to put new one in, hopefully paid for by factory!! and I made sure I siliconed it up including the wire rubber! Yep the cover is crappy even on the 06 and 07, seem to be same on 08 to!
I once had very similar problen on my 290, I put a new kit in the master and striped the slave but no success!. Felt good but after riding for 20 minutes It ended up having to much play.
After half a day I finally discovered it was simply a 'blocked' gearbox breather tube.
With the increase in temperature whilst running the expanding air would push the slave cylinder back thus leaving too much play to take up.
Hard to believe but true.
Hope this helps!
Cheers.
I personally remove rim tape and very lightly but completely smear it on the 'underside' with 'sikaflex' (the black stuff used to fit bus windows)and then refit it to the wheel. Then I fit the tyre as normal and have never had a problem. Have done this two 3 bike in the last six years.
Cheers.
