September 18, 201411 yr How do I remove the rubber boot to get to the circlip? I pulled it pretty hard but seems like the boot might rip before it pulls out. Have a 2013 TXT 280 Raga Thanks very much for the help!
September 18, 201411 yr You need to prise it out with a very thin bladed or pointed screwdriver or bradle. The boot is fitted into a lip on the cylinder.
September 22, 201411 yr Author OK here's removing the boot on my 2005 GasGas. I can do it with a fingernail. Very easy, in fact it's just barely sitting in there, a stick could knock it out. The 2013 boot acts like it's either glued in with some badass glue that sticks harder to rubber than I've ever seen, or it's retained in a different manner. But there's NO WAY to pull or pry it out like the 2005. Is there anyone with a newer GasGas who can help me?
September 24, 201411 yr Author OK got it out. My 2013 Raga has a metal ring in the lip of the boot. YOU HAVE TO PRY IT OUT FROM THE INSIDE. Pull the plunger out and stick a screwdriver thru the hole, and pry this metal ring (molded into boot lip) out ----> from the inside. It comes out easily. It is absolutely not possible to pry this boot out from the outside - the metal ring is stiff, and will not deform. You can see in the first pic, I am stretching the boot with a LOT of force but the stiff metal ring does not deform at all. I called GasGas-USA today, and they did not know this. It's possible that not every 2013 has this style brake boot.
September 25, 201411 yr Maybe thats a better design, since the older style come out too easily most of the time... Good that you made it and thanks for sharing! Edited September 25, 201411 yr by crazybond700
October 5, 201411 yr Author Yes the old style can come out if a twig drags over it. I bet if you walk around and look at bikes many of them are already out. The "new style" also has an extremely positive/firm grip around the plunger. Well finally had a half a minute to remove the circlip and take a look at the cup. As expected there was some new-bike funk on the cup seal. Wiped it off on my shirt and re-installed the plunger. It did not need any bleeding at all, it seemed to eject all the air simply upon re-inserting the plunger. I even removed the cover, to observe for bubbles ejecting, and none. I must be some kind of master mechanic ? Very nice, clutch works perfectly now, as expected. Edited October 5, 201411 yr by tsea13
October 6, 201411 yr You never really have to work hard to get the air out of the clutch master in my experience. It sorts of figures itself out. Not a lot of air gets in, and its only at the top of the system
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