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January 18th, 2021, 07:53 PM   #1
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From: Yanchep, Perth, Western Australia

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09 FE450 Clutch problem

Hi, Any help on this ongoing saga is much appreciated.

09 FE 450, when its cold the clutch works perfectly, the lever is nice & normal feeling.
The warmer it gets, the pressure/friction/engage point of the clutch moves in closer to the bars, leaving excess floppy lever movement, until the friction point is rite at the bar or beyond it, there is no clutch at all, the lever is completely floppy. To get to this stage it can take up to 15 to 20 mins of off-road riding.
Most of the time there's a tiny bit of clutch pressure rite at the bars when the lever is pulled in hard. But if I ride a bit more I'll have no clutch at all.
If I stop & turn the bike off, pump the lever the clutch comes back to normal. But when I start riding again within 7 seconds it's back to virtually no clutch.

The clutch is not Slipping.
I have already just replaced the Master Cylinder Piston & the Slave cylinder piston thinking it seems like a Hydraulic problem. But replacing these 2 has not affected it. + I have ensured there is no air in the line bleeding from the slave cylinder with a syringe.

Next step is to pull the clutch apart & have a look at it? See if I can see anything wrong.


Last edited by Paul82; January 18th, 2021 at 08:02 PM.
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January 27th, 2021, 12:10 AM   #2
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Interesting. It shld be a hydraulic issue. The clutch is a mechanical device that slips or do not slip, depending on separation of the plates..Bend plates makes poor clutch work, but the clutch works fine, and shld work even more slippery when hot.
Only the hydraulics from the pull at the lever transferred to the slave can engage the clutch.
After cool down is everything working like normall?

my 2cnts, have you checked for scratches, on the inside of the cilinder walls when you changed the seals? Specially the slave cilinder, as when it gets hot tinner oil can bypass more easily.

Last edited by HusaBergFE450; January 27th, 2021 at 12:44 AM.
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January 29th, 2021, 07:29 AM   #3
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The slave can only fail at the seal which would lead to fluid loss. If the fluid level has not dropped, I believe you’ll have to look to the master for an issue. Sorry to state the obvious, but are you using mineral oil and NOT dot brake fluid? Using Magura Blood? I was in a bind during my last slave rebuild (o-ring) and have been using light suspension fluid without issue for the past year.
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January 29th, 2021, 12:31 PM   #4
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It is very likely the slave even though you have replaced the piston and seal. They are known to fail and I had two seals go bad before moving to an aftermarket version. The oberon one for the LC4 bikes fits.

Edit: When my seal failed engine oil pushed into the clutch hydraulic system. The level did not appear to drop because the mineral oil was displaced by engine oil.
Thanks from Rainerio

Last edited by NoClassic; January 29th, 2021 at 01:58 PM.
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