hi all. 

 

Is it possible to change the piston and seals on the clutch mastercylinder WITHOUT removing the mastercylinder from the bike?  

 

any tips would be grateful thanks (y)

gasgas txt pro 250 2013 ......... small AJP ( mineral )

Edited January 29, 20179 yr by lockie28

On 30/01/2017 at 0:18 AM, oni nou said:

Yes......take the cap off the M/C then remove the fluid from the reservoir with a syringe/ scoop/ soak it up with kitchen towel etc.

Take the leaver/lever and pin/spring etc off  then remove the piston retaining clip with some circlip pliers and pull the old piston out withsome long nose pliers.

Check inside the bore to make sure it has no scoring or excessive bore wear and if ok.....

lube up the new piston with seals[using mineral oil] and carefully insert it with a twisting motion clockwise to help the cup seal enter the bore [obviously put the spring in first]

Push the piston into the bore using an appropriate screwdriver/ metal rod etc positioned in the cup at its end and put the new/old clip into its retaining groove by using circlip pliers to compress the open ends together[the clip has a sharp flat edge and a rounded edge.....the sharp edge of the clip faces outward towards you.[yes it is abit tricky]

Slowly top up reservoir with mineral oil 3/4 full and then replace the lever blade/push pin etc and flick the lever with one finger while watching [from a distance] the reservoir where you should see dislodged air bubbling up through the fluid within..... pull the lever inwards slowly at intervals also; until you feel the resistance of the clutch operating.Put the cap and diaphragm on[steady] do not tighten these screws just nip them up.Thats it.

thanks for the advice.  I replaced the seal kit today this way and it worked a treat , no hassle bleeding it either .  top job (y)

On 30/01/2017 at 0:18 AM, oni nou said: