kamahasanyi

Hi. Bike seems to be working all fine. Here is what the back of the clutch looked like.

Hey. In the end, it was me. I installed the clutch wrong. The gear exchange wasn't mating so the pushrod travelled too far, blowing the clutch slave piston seal. Thanks suzook12

I replaced the clutch plates, at 100k the bike needed it, so like for like. I opened it up yesterday and reinstalled the clutch, it didn't look right. I suspect that the gear generator hadn't matched up with the other gears or that a washer was in wrong (as you suggest), causing the pushrod to travel too far. After work, am gonna put some oil in, bleed the clutch system (again) and see what happens. Will be very happy if my stuffing up the clutch first time was the problem. Thanks.

Thanks suzook12. Possibly. rebuilt the slave cylinder with a mechanic friend, with the idea that is going to far out, as you suggest and which makes sense. Put it back on the bike. Engaged the clutch to start it, which it did. Pulled the clutch lever, felt a bit of resistance, and then bang again. Will pull the clutch and see what is going on there.

Hi. The bike is 2006 Bandit 1200 (SK6). The piston seal on the clutch reserve cylinder keeps blow. I changed the clutch. Started it up, heard a clunk from the left hand side, and then saw brake fluid leaking I rebuilt the cylinder and put in braided clutch hose. Go to bleed the clutch, just as the lever gets hard and I can start with the bleed, bang the seal goes again. Anybody have a clue what's going on? I am a bit stumped. Two main candidates: either the slave unit itself is at fault and needs to be replaced or there is something wrong with the right side pushrod (the left looks okay). I think it may be the latter. My working theory is that if the pushrod doesn't move, then the piston can't and the pressure behind the piston blows the seal. If so, clutch will have to come out again: the right side pushrod is way deep in there. I guess there is the third option of the clutch master cylinder having an issue but really doubt it. Please help. Thanks