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Old 04-17-2006, 08:24 AM   #1
1stworks OP
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Location: south side
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Clutch Problems

So Iam Going Down The The Road Above 65 Mph
And I Loose My Clutch?i Pull The Handle And No Clutch?
Iam Taking It For Some Warenty Work And Need An Heads
Up On The Clutch.i Ran It Low But Top It Off And It Works
Fine.i Think Iam Loosing Fluid?has Anyone Had This Problem?
I Have 1 Month Left On The Warranty And Hope To
Get This Fixed.i Also Have A Torn Boot From Carb To Air Box.
And I Want Them To Check My Fan.

IT IS AN 03 640 ADV

Thanks

Firstworks

1stworks screwed with this post 04-17-2006 at 08:29 AM Reason: OPPS
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Old 04-17-2006, 08:41 AM   #2
ChrisC
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Quote:
Originally Posted by firstworks
So Iam Going Down The The Road Above 65 Mph
And I Loose My Clutch?i Pull The Handle And No Clutch?
Iam Taking It For Some Warenty Work And Need An Heads
Up On The Clutch.i Ran It Low But Top It Off And It Works
Fine.i Think Iam Loosing Fluid?has Anyone Had This Problem?
I Have 1 Month Left On The Warranty And Hope To
Get This Fixed.i Also Have A Torn Boot From Carb To Air Box.
And I Want Them To Check My Fan.

IT IS AN 03 640 ADV

Thanks

Firstworks
I am travelling at highway speed (65+ mph) and I lose my clutch. The lever goes to the bar with no effect. I am going to my dealer for warranty work and would like to informed on how the clutch works before I go in. It had been low on hydraulic fluid, but when topped off it seemed OK. I may have a leak. Has anybody else experienced this? I have a month of warranty remaining and would like to get this addressed. As an aside, I also have a torn carb/airbox boot and I may have a cooling fan problem.

repaired (the caps key thing made my brain hurt )
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Old 04-17-2006, 08:53 AM   #3
1stworks OP
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Thanks

Sorry for my poor grammer.
Someone help.


firstworks
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Old 04-17-2006, 09:11 AM   #4
ChrisC
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OK, fair enough.

Does the clutch lever go to the bar with no resistance and zero clutch action? The reservoir is full, yes? Have you tried bleeding the slave cylinder?
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Old 04-17-2006, 09:25 AM   #5
1stworks OP
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Clutch

Quote:
Originally Posted by ChrisC
OK, fair enough.

Does the clutch lever go to the bar with no resistance and zero clutch action? The reservoir is full, yes? Have you tried bleeding the slave cylinder?
Lever goes to bar w/ no resistance.
Zero clutch and i did not try to bleed.
The res. is full.I ran it low but topped it off and it was ok for
one month.I dont see any leaks.
Thanks for any help.

firstworks
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Old 04-17-2006, 03:05 PM   #6
creeper
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Quote:
Originally Posted by firstworks
Lever goes to bar w/ no resistance.
Zero clutch and i did not try to bleed.
The res. is full.I ran it low but topped it off and it was ok for
one month.I dont see any leaks.
Thanks for any help.

firstworks
Hummmm....

Could be air in the line... lots of air. Or, it could be a faulty master or slave cylinder, or a major leak (which would be a faulty slave cylinder) inside the engine.

Just out of curiosity, what did you put in the reservior when you topped it off?

Thats all I got.
C
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Old 04-17-2006, 03:38 PM   #7
1stworks OP
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Thanks

I Used Mineral Oil Like It Says To Use.
Why Does It Work When I Filled It Up.
If There Was Air In System Would The Clutch Come Back?
It Looks Like The Slave Is Attached To Outside Of Case?
What Will I See Inside The Case?

Thanks For Your Help
Firstworks
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Old 04-17-2006, 04:19 PM   #8
creeper
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Quote:
Originally Posted by firstworks
I Used Mineral Oil Like It Says To Use.
Why Does It Work When I Filled It Up.
If There Was Air In System Would The Clutch Come Back?
It Looks Like The Slave Is Attached To Outside Of Case?
What Will I See Inside The Case?

Thanks For Your Help
Firstworks
You didn't say that it works when you fill it up, you said you topped it off a month ago and it was OK 'till now.

It might come back, as the system is designed to self-bleed... assuming the master cylinder is higher than the hose.

The slave is outside, but attached to the case... a small leak may not be readily visible.

C
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Old 04-18-2006, 05:13 PM   #9
Esteban
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Quote:
Originally Posted by ChrisC
I am travelling at highway speed (65+ mph) and I lose my clutch. The lever goes to the bar with no effect. I am going to my dealer for warranty work and would like to informed on how the clutch works before I go in. It had been low on hydraulic fluid, but when topped off it seemed OK. I may have a leak. Has anybody else experienced this? I have a month of warranty remaining and would like to get this addressed. As an aside, I also have a torn carb/airbox boot and I may have a cooling fan problem.

repaired (the caps key thing made my brain hurt )

I am travelling at highway speed (65+ mph) and I lose my clutch. The lever goes to the bar with no effect. I am going to my dealer for warranty work and would like to informed on how the clutch works before I go in. It had been low on hydraulic fluid, but when topped off it seemed OK. I may have a leak. Has anybody else experienced this? I have a month of warranty remaining and would like to get this addressed. As an aside, I also have a torn carb/airbox boot and I may have a cooling fan problem.

Repaired the orange on black, made my eyes hurt. That should just about do it, now where were we ?

Esteban
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Old 04-23-2006, 01:38 AM   #10
acupuncture4u
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Quote:
Originally Posted by Esteban
I am travelling at highway speed (65+ mph) and I lose my clutch. The lever goes to the bar with no effect. I am going to my dealer for warranty work and would like to informed on how the clutch works before I go in. It had been low on hydraulic fluid, but when topped off it seemed OK. I may have a leak. Has anybody else experienced this? I have a month of warranty remaining and would like to get this addressed. As an aside, I also have a torn carb/airbox boot and I may have a cooling fan problem.

Repaired the orange on black, made my eyes hurt. That should just about do it, now where were we ?

Esteban
I was kinda enjoying the orange. KTM getting in the blood I guess...
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Old 04-23-2006, 03:13 AM   #11
Max Kool
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You filled it up with MINERAL OIL??? Like in "mineral engine oil"??

I'd say bleed that sucker thouroghly. Flush it with at least half a quart of DOT 4 (or 5.1) to remove it. I 've never heard of using engine oil in a hydraulic clutch system.

But the fact that you had to refill it should have made some sirens and alarm bells ring in the first place. The volume of the master cylinder should be more that enough to compensate for clutch wear, won't it?

I suspect the slave cylinder is leaking.
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Old 04-23-2006, 10:03 AM   #12
Yellow Pig
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Quote:
Originally Posted by Max Kool
You filled it up with MINERAL OIL??? Like in "mineral engine oil"??

I'd say bleed that sucker thouroghly. Flush it with at least half a quart of DOT 4 (or 5.1) to remove it. I 've never heard of using engine oil in a hydraulic clutch system.
No, No!

It's a Magura hydraulic clutch and uses a mineral biodegradable clutch oil, kind of like the stuff in mountainbike brakes.
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Old 06-29-2006, 10:09 AM   #13
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busted clutch eh?

O-ring in either the master cylinder or slave cylinder goes out!
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Old 02-21-2007, 07:58 AM   #14
enduro-ince
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Anybody rebuild their slave cylinder with a rebuild kit?
Easy enough for a mechanical moron to do?
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Old 02-21-2007, 08:45 AM   #15
cevquit
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Quote:
Originally Posted by Max Kool
You filled it up with MINERAL OIL??? Like in "mineral engine oil"??

I'd say bleed that sucker thouroghly. Flush it with at least half a quart of DOT 4 (or 5.1) to remove it. I 've never heard of using engine oil in a hydraulic clutch system.

But the fact that you had to refill it should have made some sirens and alarm bells ring in the first place. The volume of the master cylinder should be more that enough to compensate for clutch wear, won't it?

I suspect the slave cylinder is leaking.
NO NO NO NO, Magura products use a mineral oil NOT BRAKE FLUID.
Brake fluid will kill your Magura Hydraulic clutch. Check for blockages in the cranckcase or head breather vent. If they are blocked, engine case pressure will push on the piston of the slave at higher rpm. The slave rebuild is a complete set up, piston and cylinder, it bolts to the outside of the case.The slave gets quite a bit of wear and replacing the oring will fix it for a short while, but the worn area of the slave will cause the new oring to wear faster, a couple month fix at best.There are a couple of nooks and crannys in the slave that take quite a bit of bleeding to get all of the air out. It took three bleeds to get all the air out of my friends clutch on his 03.
On a funny related side note, always check your fluid before using. When we went to baja last month, my buddy, who has been going through the whole worn clutch thing, filled his clutch with fluid.After afew days of riding it needed a topping off, so when he takes off the cover the master is full of goo,WTF.So he goes to the oil box gets the white bottle of magura blood, when he opens it it hits him, its not magura blood but window washing soap. The two come in exactly the same bottle, and the labels had come off of both. Rode for 500 miles with soap in his clucth.
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