clutch problems MY FIRST BERG HELP WANA RIDE this thing just

sneek · Mar 6, 2008

I got this bike home today. Bought it as is for a too good to pass up price. I had no pressure on the clutch so I tried to back bleed it and it will not even push the smallest ampont of ATF fluid through. I had the resivior cover off and the bleed nipple cracked open and checked the hole in it for a clog and could blow through it.
I was able to pump the lever and get some air out but not nearly enough to get it to work so I can ride. I own a KTM 300 EXC and have no problems back bleeding that clutch .

Any suggestions on the problem?? Man I want to ride this thing and this is the only thing keeping me from that.

steve · Mar 6, 2008

Does fluid come out of the bleeder? If you remove the bleed screw all together does fluid come out? Aqueeze the level? If it goes one way, then it should go the other.

Steve

scrapveiw · Mar 6, 2008

there is a tiny hole in the the master cylinder reservoir that feeds the piston in the master , these sometimes block up and the piston in the master is unable to draw fluid in to the master cylinder bore , in this Case the existing fluid and or air just travels back an forth along the pipe as no new fluid can be introduced into the hydraulic system,

if that seems ok then get a syringe connected to the bleed nipple and try to draw the fluid through the system.

regards

scrap

berger · Mar 6, 2008

What year is the bike and why are you using ATF? Most take mineral oil.

whosahberg · Mar 6, 2008

year and miles ???

SMCS · Mar 7, 2008

Undo or remove the bleed nipple on the clutch slave, screw out the lever adjuster all the way as this lets the master cylinder piston refill, then try squeezing the lever to see what appears down below, before taking another squeeze lightly push the clutch lever outwards to help the piston area recharge and repeat the proccess.If fluid appears just keep on going and If nothing is coming out the bottom you will have to inspect for line crush or faulty mastercyclinder seals? The slave is so basic I doubt this is your problem. You can use 2.5fork oil as this is a mineral oil suitable for your clutch.
Best Regards
Sutto

sneek · Mar 8, 2008

Got the answer at KTM talk

Could have been anything but someone over at KTM Talk suggested the little rod on the lever that pushes the master cylinder in was it too far causing me not to be able to back bleed .
I removed the lever completely and back bleed the clutch and that was the problem all along. I just wanted to lt everyone know in case they run into this on their bike. Thanks for all the suggestions.
I got the bike running and takes 5-6 kicks to get it fired up. This thing has tons of power everywhere. I have one problem though. It stalles / flames out in the tight stuff and just today after jumping it and pulling into a little turn around place ideling to turn in 1st gear and it stalls if I do not keep the RPMs up above idle speed. The bike idles fine but will stall / flame out when in the tight stuff but will start right back with 2-3 kicks.
Any suggestions would be appreciated. Thanks, Justin this bike is a 2002 501 all stock with no mods to it .

Taffy · Mar 17, 2008

RE: Got the answer at KTM talk

YOU MUST GET A NEW PLUG. A NIPPON IXU24 IS THE PLUG OF CHOICE.

what is your location?

regards

Taffy

clutch problems MY FIRST BERG HELP WANA RIDE this thing just

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