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Old 04-05-2011, 09:52 AM   #6151
Gerst
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[QUOTE=Droptarotter;15588791]Some of you were asking about the auxiliary lights on my bike. I do not know too much about them, but here are some shots of how the PO mounted them.

Drop,
thanks for taking the time to take and post the pics
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Old 04-11-2011, 08:01 AM   #6152
TheVikingRider
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Was riding yesterday and my clutch went out. Looked and was very low on mineral oil in the hydro clutch.

Put some in and must be some air in the line (to be expected) cause the clutch was acting funny.

Whats the procedure for bleeding the clutch?
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Old 04-11-2011, 05:00 PM   #6153
nick g
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slave cylinder O ring?
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Old 04-11-2011, 06:45 PM   #6154
GreyDawggg
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Yes if you never saw any leaks from the cables or anywhere the chances are very likely that your slave cylinder o-ring has called it a day. If it were me I would pull the slave cylinder off and check it out, replace the o-ring with a good viton o-ring and bleed the system with some new mineral fluid. You bleed it from the bottom up. It's like bleeding brakes you need a syringe with 6mm id tube to go over the little nipple and as you crack it you slowly push the new oil through. You might have to do it a few times to get all the air out (I did) and you can see little bubbles escaping the top reservoir. It is good to have someone help you.

Cheers
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Old 04-11-2011, 08:02 PM   #6155
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Quote:
Originally Posted by GreyDawggg View Post
Yes if you never saw any leaks from the cables or anywhere the chances are very likely that your slave cylinder o-ring has called it a day. If it were me I would pull the slave cylinder off and check it out, replace the o-ring with a good viton o-ring and bleed the system with some new mineral fluid. You bleed it from the bottom up. It's like bleeding brakes you need a syringe with 6mm id tube to go over the little nipple and as you crack it you slowly push the new oil through. You might have to do it a few times to get all the air out (I did) and you can see little bubbles escaping the top reservoir. It is good to have someone help you.

Cheers
I agree, change the o-ring in the slave. For bleeding, I used a syringe and clear vinyl hose to bleed from the bottom up as GreyDawgg suggests. Once you are done that, give it a few pumps, then, while holding the clutch lever in, just crack the bleed nipple on the slave slightly, and you will probably find one last bubble hanging out in the slave, at least I did.
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Old 04-12-2011, 05:01 AM   #6156
dirty_sanchez
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The clutch went soft on me on the '03 at a real-live fork in the road up in AR a few years back where a guy named one-legged Bill who owned a mule on a rope came to the rescue.

How are you guys removing the piston in the Slave Cylinder in order to gain access to the O-Ring?

I remember reading that the Slave Cylinder O-Ring is the very same size as the one used in the counter shaft O-Ring is this correct?

Dirty
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Old 04-12-2011, 05:27 AM   #6157
Alik
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I have done these twice already on my short career with the bike :)
Remove the piston in the slave by blowing it out with compressed air or your mouth - the choice is yours :) Watch out for the small spring and the ball.

Why twice you may ask… I somehow managed to pinch the silicon o-ring I have used from the CS-seal kit I have spare.
I don't know why and how but I have pulled it out again and it was pinched and destroyed. Removed, cleaned and installed real black o-ring I have buyed in the small shop aka 'everything from rubber' nearest to my place. It was maybe 1$ investition.
So get the right o-ring don't be skimpy ;)

I learned the thing by loosing all of the pressure in the clutch overnight. I have a funny feeling that the bleeding is not quite easy in the clutch. I have bled it from the bottom and it was endless repetition of pumping these small bubles out of the reservoir.
Don't loose Your faith ;) it will finally get hard the clutch I mean.
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Old 04-12-2011, 06:17 AM   #6158
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My clutch went last week too. Where do you get o-rings other than the KTM rebuild kit?
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Old 04-12-2011, 07:05 AM   #6159
B-Rod
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Quote:
Originally Posted by dirty_sanchez View Post
How are you guys removing the piston in the Slave Cylinder in order to gain access to the O-Ring?

I remember reading that the Slave Cylinder O-Ring is the very same size as the one used in the counter shaft O-Ring is this correct?

Dirty
It is Gunnerbuck that figured the countershaft o-ring is the same, so I went ahead and ordered a couple. Used one, and one as a spare, and the best part is I recall they are less than $3.

Quote:
Originally Posted by EdGear View Post
My clutch went last week too. Where do you get o-rings other than the KTM rebuild kit?
If your bike has been sitting around for a while, you may just be able to top off and go. Mine goes soft over winter, and although I squeeze the lever every so often, it is soft the day I want to ride it.
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Old 04-12-2011, 07:25 AM   #6160
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Thanks for the replies fellas. I guess Ill order a countershaft o ring and rebuild the slave.
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Old 04-12-2011, 10:31 AM   #6161
EdGear
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I didn't ride a couple months because of foot surgery but have ridden a couple times about a week or two apart. No sense of loss of clutch those times or I did not notice.

The slave cylinder looked ok except for some discolorations, freckles. Look like metal coating imperfections not wear or o-ring material. O-ring looked fine through a magnifying glass. Probably the o-ring dried up too much while idle and fluid leaked into engine case then first use could have pinched or twisted the o-ring losing the rest of the fluid.

Ordered the Slave cylinder kit already, will get a countershaft o-ring or two for spares.

Thanks,
Ed
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Old 04-12-2011, 10:57 AM   #6162
Alik
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A propos slave cylinder…

Here is a official mounting procedure described by Tseta in this post.

http://www.advrider.com/forums/showp...6&postcount=31
(…)
1. Mount the slave cylinder with the new clutch release gasket
(KTM part no 586.32.065.000).
2. We recommend to moisten the slave cylinder fixing screws with medium liquid screw lock compound (Loctite 243), during all kinds of service on LC 4 engines.
Important is to tighten the cylinder screws in the order – centre-bottom-top – with 8 Nm
torque. After one minute tighten the screws in this order again.
Finally, please bleed the clutch system very precise !
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Old 04-13-2011, 05:50 AM   #6163
garfey
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Wicked Just Lurking in the Weeds, Guys ...

... and haven't had any of the problems ............. yet! Also, I've been tied up with other bikes recently - buying, repo'ing, fixing, selling, etc. Been taking mental notes and y'all are posting some really good dope. Thanks!
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Old 04-13-2011, 09:58 AM   #6164
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Hey garfey, taking a little time off from Jenny's thread?
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Old 04-13-2011, 11:46 AM   #6165
sjeproductions
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Quote:
Originally Posted by dlh62c View Post
Let us know how the windscreen works out. I've been running a Laminar lip for the past 28,000 miles on my 07. I'm looking for something that might be better. With the added stress on the front mask, don't be surprised if the mask mounting points on the gas tank start snapping off. It's easy to fix or replace them.

daryl
So far the hyde screen is doing well. It certainly helps with air flow, taking a lot of stress off the arms and chest at highway speeds and doesn't seem to cause too much deflection to the OEM fairing on or off-road. I've also found the backside of the screen is a handy place to write notes with a dry-erase marker, when it's late in the day and your brain isn't firing on all cylinders or even one.

Daryl, thanks for the 411 on the mounting points, I'll keep an eye on them.
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