KTM 950/990Adv clutch master cylinder resleeving.

Discussion in 'Vendors' started by gefr, Dec 17, 2013.

  1. gefr

    gefr Life is a trip

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    I can resleeve your clutch master cylinder with inox sleeve, 100€, post costs included + 35€ for the KTM 10.5mm spare piston # 50302032000 (you could buy that yourselves) 4 tiny bearings are also installed in the lever joints, to compensate for lateral forces
    Total cost 135€.
    You will need to send me the old master cylinder and clutch lever with their bushings..

    Alert: You need to declare low value to the post office, lower than $28 in order to avoid customs charges, if outside E.U..

    Cheers.

    P.S. In the following pictures there is an aftermarket lever I bought. Unfortunately it lacked the necessary extrusion to operate the clutch safety switch, so I had to fabricate it with some glue. I bought this when my original lever developed lateral play. When I realized where my original lever was worn I installed some bearings similar to the one you can see on this spare one and put it back in operation (140k kms).




    This little cylindrical part is holding the red adjuster. It is machined to fit with the 2 bearings. It is shown in the next picture mounted on the lever.

    [​IMG]
    [​IMG]
    Two bearings are mounted on the lever joint with the red adjuster
    [​IMG]
    [​IMG]

    I install ball bearings same to all places. Makes the assy bulletproof.

    So cost is 135€ for the upgrade.

    Cheers.
    #1
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  2. ICERIDER

    ICERIDER Adventure Rider

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    Hey! Sounds like yet another great fix for a known weakness. Well done on working this one out. I want one!

    I remember seeing your posts on this subject a while back. Do you now have an extensive test period behind you to verify the quality and projected service life?

    So you bore out the Master, fit a SS liner, and use the OEM piston kit?
    #2
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  3. gefr

    gefr Life is a trip

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    I have installed mine for a year of everyday riding and a friend's for the same period with very good results - light clutch feel. So last month I installed another 2 of them and are working satisfactorily. I believe I am ready to go worldwide, so here it is. Photos will follow when ready. Rechecked costs with my workshop so the price is accurate.
    The sleeve is installed in the bored out to 11.0mm cylinder. The sleeve inside diameter is 10.5mm.
    Cheers.
    #3
  4. ICERIDER

    ICERIDER Adventure Rider

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    Sounds great. I'd rather see you charging the correct amount and keep at it!

    The drop to 9mm piston seems to work then? I've seen others use a 9mm Magura. Less lever force but more travel. I assume it's still a workable lever throw to use 1 or 2 fingers.

    Looking for a used master to push your way.:D
    #4
  5. LukasM

    LukasM Long timer

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    I've been waiting for a long time for somebody to offer this service, as I know of several people with worn out clutch MCs.

    Do you know if it will work on MCs with smaller diameter, can you bore them out enough to fit your sleeve? KTM and Husaberg also came with 9, 9.5 and 10.5 MCs.
    #5
  6. gefr

    gefr Life is a trip

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    I haven't seen the m/c you are talking about. However if you have any part numbers I could ask at the KTM dealer to show me one and check it out with my machinist. Maybe Husaberg parts are same with some KTM ones. My guess is it is possible.
    Cheers.
    #6
  7. keener

    keener Speed changes you.

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    Looks like a great mod. What is the number/code of the bearing you used inside the leavers?
    #7
  8. gefr

    gefr Life is a trip

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    The codes on my receipt are: MR95ZZ(ML500 but do not know the manufacturer.
    Cheers.
    #8
  9. keener

    keener Speed changes you.

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    Thx for posting that.

    <table class="cdsShowProductAttributeTable ke-zeroborder" cellpadding="0" cellspacing="1" border="0" width="100%"><tbody><tr class="cdsShowProductTableHeadRow"><td style="font-weight:bold;padding:3px 6px;font-size:14px;border:0px solid #999999;width:237px;" bgcolor="#FFFFFF">
    </td> <td style="font-weight:bold;padding:3px 6px;font-size:14px;border:0px solid #999999;width:236px;" bgcolor="#FFFFFF">MR95zz</td> </tr> <tr class="cdsShowProductTableEvenRow"><td id="avl_a01_bore_dia" style="border:0px solid #999999;padding:3px 6px;" bgcolor="#FFFFFF">Bore Dia (d)</td> <td id="avv_a01_bore_dia" style="border:0px solid #999999;padding:3px 6px;" bgcolor="#FFFFFF">5mm</td> </tr> <tr class="cdsShowProductTableOddRow" style="background-color:#eeeeff;"><td id="avl_a02_outer_dia" style="border:0px solid #999999;padding:3px 6px;">Outer Dia (D)</td> <td id="avv_a02_outer_dia" style="border:0px solid #999999;padding:3px 6px;">9mm</td> </tr> <tr class="cdsShowProductTableEvenRow"><td id="avl_a03_width" style="border:0px solid #999999;padding:3px 6px;" bgcolor="#FFFFFF">Width (B)</td> <td id="avv_a03_width" style="border:0px solid #999999;padding:3px 6px;" bgcolor="#FFFFFF">3mm</td></tr></tbody></table>http://www.lily-bearing.com/en/cp/mr95zz.htm

    Does that seem right? only 3mm tick?!
    #9
  10. gefr

    gefr Life is a trip

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    I installed 2 of them at the edges of the retainer cylinder that holds the red colored adjuster.
    I also installed another 2 of them at the main lever pivot. The lever needs a tiny bit boring, since ID is 8.0mm while bearing OD=9.0mm.
    They fit nicely and stabilize lever operation.
    Cheers.
    #10
  11. Peanuts

    Peanuts Long timer

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    I love the concept!

    MR85ZZ is 5x8x2.5, I wonder if that will fit the lever pivot without machining? Make a small spacer to sit between the bearings.

    It would also mean less metal is removed from the lever where the adjuster passes through.
    #11
  12. gefr

    gefr Life is a trip

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    So machining with a drill was nessecary to make the hole round again. The lever has plenty of material at this region.
    Cheers.
    #12
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  13. Bonnie & Clyde

    Bonnie & Clyde Wishing I was riding RTW

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    PM incoming
    #13
  14. Bonnie & Clyde

    Bonnie & Clyde Wishing I was riding RTW

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    I sent my 2006 adv clutch lever to gefr from the usa to greece for the re-sleeve service. Prior to sending it in I was leaking at the lever and my actual lever had slop at the pivot/joints. It would rattle while off road. My clutch was dragging just a bit too. I was always adding fluid.

    So I got the lever back and Im very pleased. The bearings he puts in the two pivot joints takes out all the loose slop and play and all new seals. I installed it and it works perfect. No more clutch drag either. Well worth the time & money.
    #14
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  15. Bonnie & Clyde

    Bonnie & Clyde Wishing I was riding RTW

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    update I have put 8 thousand miles on my re-sleeve still works perfect. Im glad I sent it to gfr
    #15
  16. Loui€

    Loui€ Rides With Reindeer

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    Hi!

    Do you still have this service, same price? I have a "leaky cauldron" again, air gets into my clutch-system.

    is there a special reason or need to put that inox sleeve in, is that cylinder wearing off, to oval or something like that? why not just buy new cylinder, "CLAMP MIRROR WITH CLAMP" 60002044000 is about 47€, half price, and then new spare piston?

    my 1st (factory) piston did about 100 000kms, next ktm-spare 50 000kms, now leaking again after another 50 000kms...

    that "ball bearings" sounds very good idea, though - my "red-part-hole" is oval and clattery, and lever is a bit loose, too.
    #16
  17. AndreSpain

    AndreSpain n00b

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    Hi! I am interesed in doing the resleeving to my cluth pump. How I can talk with you! I am from Spain and I dont know how and where send It!
    Thanks
    #17
  18. gefr

    gefr Life is a trip

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    The reason we are installing a s/s sleeve is to give it longevity. The aluminum is soft and after 80,000kms or so it reaches its service life. The part you refer to is only the mirror clamp with the mirror possibly. It definitely does not include the cylinder. The joints wear out alowing the lever to move sideways, wearing the cylinder or possibly the metal part of the piston touches the cylinder. Ball bearing restrict side movements.
    Cheers
    #18
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  19. Loui€

    Loui€ Rides With Reindeer

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    ok, thanks for info and correcting me, cylinder is 60002030000, "MASTER CYLINDER MAGURA D=10.5", ~ 300€... :cry

    so, how to proceed to get this job done? PM you?

    edit:
    all clear, PM is the way.
    #19
  20. Robert TIlssen

    Robert TIlssen n00b

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    @gefr
    PMed you

    @others
    Any more positive feedback on this? (as opposed of alternatives ..Magura or Clake .. what else folks have gone for?)
    #20