Anyone else ever have this happen?

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ninjamunky85

ninjamunky85

Joined
Sep 27, 2013
Messages
81
Location
Ohio
Yesterday I was riding my '10 FE450 on some local trails when I pulled my clutch lever and it snapped. Except when I looked closer it turned out that it wasn't the lever and was actually the clutch master cylinder that snapped.



It looks like the PO had already partially broken it and then tried to JB weld it back together, which didn't work.



I looked online and a new master cylinder costs over $300. So now I'm not sure what to do to fix it.

Then this morning I went to move the bike in the garage and this happened.



Bike damn near knocked me over, but I was able to catch it and reach my stand nearby. I have another kickstand that I bought so that I can shorten it when I convert the bike to sm. I plan on switching back and forth between the off road and street wheels so I need two kickstands.

Can this be fixed? It looks pretty bad. I don't get why the kickstand snapped, but it seems to me like something that shouldn't happen.
 
Well I guess for right now I'll just try to epoxy the clutch cylinder back together. I found some used ones on ebay for around $140, so that's an option.

How much should it cost me to have it professionally welded, or is that even an option?
 
Not sure if that master will weld easily. I believe it is magnesium. It does weld like alu, but will catch fire and is extremely tough to put out. I see there are some that will weld it inside a blasting cabinet plumbed with shielding gas.

Keep your eye out for a ktm master. I think your stock one is like 9.5mm bore, written somewhere on the bottom side. Some like a larger bore like 10.5 or larger.

Those kick stands are super fragile and known to break. There is an aftermarket one for ~$120 that is much stronger.
 
Ok thanks, I was kind of thinking that the master cylinder might not be able to be welded. I'll just hope that the epoxy I fixed it with will hold for a while until I can grab another cylinder.

BTW do you have a link for the kickstand you were talking about.
 
OK so I got the master cylinder epoxyed back together, and it feels pretty strong so hopefully it will hold for a while. I've got the clutch lever mounted now, but it isn't doing anything.

Is there some kind of trick to installing the clutch lever on these bikes? I see that there is a little rubber boot that attaches to the clutch lever. I attached it to the lever, but it keeps slipping off. I'm guessing that has something to do with the lever not working?
 
Master cyl is not magnesium, from what I know it is, unfortunately, very low quality material, some kind of scrap metal melted and cast. It can be welded by most welders but you need a bit of luck because it has a kind of air bubbles inside of the cast...

Sorry, don't know how to explain it better in english....

M.
 
Never mind I found out what the problem was. There's a pin that is missing. Doesn't really matter though cause when I replaced the pin and tried the clutch the cylinder snapped again. The epoxy didn't hold at all. So now I'm going to ebay to find another master cylinder.
 
just a note, i have that pro billet kick stand on my 2011 FE390. I use it for both dirt wheels and my 17" supermoto setup.

with the 17" wheels, the bike stands almost perfectly straight up. In some cases depending on where i park, i just lean the bike against a wall or something, as the stand makes the bike way to tippy :)

great stand otherwise, but it is very tall/long. Even more so than the stock one.
 

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