My 2002 Pro has always had clutch problems since I had to bleed it the first time. Fast forward a few years and new clutch plates along with a transmission rebuilt helped alot. Finally got it dialed for the last ride and it stopped being a clutch altogether.

It is leaking fluid out of the joint where the line goes into the case side. I pulled it out and the threads inside look smashed, almost like someone decided the threads on the line were close enough and worked it in. There were a couple threads that came out of the case too. Looking into the hole there is a shelf and beyond the shelf there are good threads. It looks like the piece threaded in could have been too big. Ill get pics later today.

Any suggestions on how to fix this?

there is an upgrade kit. http://www.trialspartsusa.com/racing-parts.html or a used case on Ebay.

Edited September 20, 201411 yr by lineaway

How is an upgrade kit going to help with a leak? The parts in the upgrade kit are only internal.

Did you notice that it is the whole cover! The upgrade fixes the problems of the early models. It is the correct fix. Maybe you should try your dealer.

Edited September 23, 201411 yr by lineaway

No dealer within several hundred miles that I know of. Nearest is lewisport.

I missed the cover. Is it the new aluminum one with no magnesium?

* GASGAS Pro Technical bulletin June 8th, 2010

Application: 2002~2009 GASGAS “Pro” model motorcycles.

Subject: Clutch slave cylinder repair hints, applicable o-rings, and alternative parts availability. Information on water pump updates. Periodic maintenance and repair.

GENERAL CLUTCH INFORMATION

For 2002 GASGAS pro. The “clutch cover” update kit:

Beginning in the 2005 model year, all Pro model hydraulic clutch systems use mineral oil. (Applicable to the 2004 Adam Raga special edition models also)

A “kit” is available to convert the clutch cover~slave unit on 2002 Pro motorcycles, into the improved 2003-06 aluminum redesigned version. This kit includes all components necessary to convert from DOT4 brake fluid to Mineral oil.

NOTE: THE BRAKES USE DOT 4 FLUID. NEVER INSTALL MINERAL OIL IN A BRAKE SYSTEM!

The kit includes the following: One 2003~06 type aluminum clutch cover (2002 models are magnesium) all necessary o-rings gaskets, and seals. A seal kit to convert the master cylinder on the handlebar to accept the mineral oil. Contact the GASGAS dealer nearest you for more information. GASGAS part number MT280532001CR

No dealer within several hundred miles that I know of. Nearest is lewisport.

I missed the cover. Is it the new aluminum one with no magnesium?

Try Gran Prix Cycle in Albany, they are the Gas Gas dealer for the area. Gary and Mike are good guys.

Try Gran Prix Cycle in Albany, they are the Gas Gas dealer for the area. Gary and Mike are good guys.

Will do. Ill give them a hollar and see what they say and if they will ship.