570 Clutch goes spongy when HOT

Lancer · Sep 9, 2018

I am having a problem with the clutch on my 570 acting up when the engine gets hot. It's as if there is air in the system, the clutch lever will act like it has air in it progressively until the lever goes to the bars. Pump the lever 3 or 4 times and the clutch comes back...wait a couple of mins and there's no clutch again. It mostly does it when the engine gets hot......The thermo fan is running and there is no fluid loss. I have replaced the oil and bled the system a number of times with 15W mineral oil as recommended and I just fitted a slave cylinder kit and checked the bleed hole in the master cyl and it seems to be fine. I read on here, there were a few other guys having the same problem and there was no definitive answer so I am putting it out there in case someone has had similar problems and found how to fix it. Thanks

Ook Peter · Sep 9, 2018

Had similar problems on my FE390, replaced the complete slave cylinder and now have a light, reliable and stable working clutch. Did some work on the old unit afterwards and will see if it is refurbisable as soon as this one fails. From what I read and heard these slave cylinders are prone to failure.

Lancer · Sep 9, 2018

Ook Peter said:
Had similar problems on my FE390, replaced the complete slave cylinder and now have a light, reliable and stable working clutch. Did some work on the old unit afterwards and will see if it is refurbisable as soon as this one fails. From what I read and heard these slave cylinders are prone to failure.

Thanks...I have pretty much eliminated it down to the slave cylinder but thought it better to ask before I buy

Did you fit a Berg slave or a KTM.......The latter is half the price and the seals and all the other parts are available. Going by the spares pics I see the KTM piston appears slightly different to the Berg. The gasket and O'ring is the same so I am 99.9% sure it's going to fit......Maybe someone who has done it or knows can let us know

Thanks

Lance

TomTom · Sep 10, 2018

Did you push the oil from the slave and up with a syringe or such? If not theres likely the problem, its close to impossible doing it any other way without air being trapped. 2c.

Lancer said:
Thanks...I have pretty much eliminated it down to the slave cylinder but thought it better to ask before I buy

Did you fit a Berg slave or a KTM.......The latter is half the price and the seals and all the other parts are available. Going by the spares pics I see the KTM piston appears slightly different to the Berg. The gasket and O'ring is the same so I am 99.9% sure it's going to fit......Maybe someone who has done it or knows can let us know

Thanks

Lance

Lancer · Sep 11, 2018

TomTom said:
Did you push the oil from the slave and up with a syringe or such? If not theres likely the problem, its close to impossible doing it any other way without air being trapped. 2c.

Hey Tom, no I haven’t so today I got a syringe and reverse bled it and didn’t notice any air come up to the reservoir.

Seeing as I had the slave off I pulled it apart and found the sealing ring was quite out of shape so I fitted a new ring and bled it again with the syringe

I’ll see if that fixes it on the next ride

Ook Peter · Sep 12, 2018

Lancer said:
Thanks...I have pretty much eliminated it down to the slave cylinder but thought it better to ask before I buy

Did you fit a Berg slave or a KTM.......The latter is half the price and the seals and all the other parts are available. Going by the spares pics I see the KTM piston appears slightly different to the Berg. The gasket and O'ring is the same so I am 99.9% sure it's going to fit......Maybe someone who has done it or knows can let us know

Thanks

Lance

I got a KTM one since they did not have Husaberg parts. Does the job just as good imho.

chaysr · Jan 14, 2024

Lancer said:
Hey Tom, no I haven’t so today I got a syringe and reverse bled it and didn’t notice any air come up to the reservoir.

Seeing as I had the slave off I pulled it apart and found the sealing ring was quite out of shape so I fitted a new ring and bled it again with the syringe

I’ll see if that fixes it on the next ride

Sorry for digging up an old thread - I have this exact clutch fade/floppy lever problem on my 2011 FE450. It only really happens in technical riding when the engine get hot and the thermo fan is working hard.

Did you find a solution to this? Replacement slave cylinder maybe?

rikschipp · Jan 28, 2024

chaysr said:
Sorry for digging up an old thread - I have this exact clutch fade/floppy lever problem on my 2011 FE450. It only really happens in technical riding when the engine get hot and the thermo fan is working hard.

Did you find a solution to this? Replacement slave cylinder maybe?

Bleed with quality ATF after checking slave. Pop it off, clean out well, replace o-ring if necessary, polish bore if needed, back flush while holding piston in. Job done. May need master cyl kit.

Connecticut_FE550 · Jul 26, 2024

rikschipp said:
Bleed with quality ATF after checking slave. Pop it off, clean out well, replace o-ring if necessary, polish bore if needed, back flush while holding piston in. Job done. May need master cyl kit.

Any thoughts on my situation?

I rebuilt the master cylinder & replaced the o-ring in the slave. The bike has sat for 2 months due to repairs but now the clutch is only half disengaging. Right after the rebuild it worked perfectly.

If I put the bike in first, pull the clutch lever, I can feel that the clutch only half disengaged. The picture is the mineral oil I used, maybe it doesn’t agree with the o-ring?

I also had the clutch cover off to do the water pump seal and I ran into the kick start issue mentioned in another thread. I’ll do Taffy’s 1mm washer behind the sledge mod to prevent this slip. But my point is I’ll have the clutch cover off again, maybe there was something I messed up while I was in there? I did pull the clutch while the cover was off.

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570 Clutch goes spongy when HOT

Lancer

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Ook Peter

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