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Old 03-02-2013, 08:13 PM   #1
dino2000 OP
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Joined: Dec 2003
Location: Sacramento,Ca.
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02' 520 EXC clutch......HELP!

Bike is new to me. Very low hours and very clean. The PO had a Rev-loc in it but took it out before he sold it to me. The clutch lever was a lil mushy when I test rode it but it had been sitting for a long time and i figured it need to be bled. I bought the rebuild kit for the clutch master and bled the system.

Rode all day today and lever would go limp while ripping thru the woods. i could stop and pump the lever and get it back but i dont know what the fix is.

PO installed "new" plates.( any chance they arent in right)
clutch does not slip.
clutch master rebuilt and bled by me and the shop mech.

any help with this would be appreciated

Dino
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Old 03-04-2013, 06:40 AM   #2
topender
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slave cylinder needs a rebuild, very common "O" ring failure.
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Old 03-04-2013, 10:08 AM   #3
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Yep, do the slave cylinder rebuild. The clutches are pretty durable on these bikes!

Cheers
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Old 03-04-2013, 01:27 PM   #4
Off the grid
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Slave cylinder and make sure you bleed it correctly.

IMO, I wish there was an option to use a cable-actuated clutch. The hydraulic clutch, while buttery smooth, is an option that most casual riders don't need, and sometimes leads to ride-ending failures. (my slave went 10miles into the best ride of the season)
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Old 03-04-2013, 04:49 PM   #5
dino2000 OP
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thanks a million!!

Gents,

I thank you for all the advise but if the slave was bad, how could I pump it back up? If it is leaking, wouldn't i be able to see the fluid going away?
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Old 03-04-2013, 05:48 PM   #6
Droptarotter
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You should be able to notice the fluid disappearing from the master cylinder, but it will not take much of a leak for your lever to go away, so by the time you have lost your lever, the fluid level might only be down a couple of millimetres.....too little to notice!

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Old 03-04-2013, 06:09 PM   #7
dino2000 OP
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I shall re-build! Thanks again.........i'll let y'all know how it shakes out.
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Old 03-05-2013, 10:08 AM   #8
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Quote:
Originally Posted by Off the grid View Post
Slave cylinder and make sure you bleed it correctly.

IMO, I wish there was an option to use a cable-actuated clutch. The hydraulic clutch, while buttery smooth, is an option that most casual riders don't need, and sometimes leads to ride-ending failures. (my slave went 10miles into the best ride of the season)
1 maintenance issue and your ready to go back to a stone age cable? Ive had many hydraulic clutch KTM's and have never had a single problem.
Tools are made to keep bikes in good shape,I use em.
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Old 03-05-2013, 03:12 PM   #9
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1 maintenance issue and your ready to go back to a stone age cable? Ive had many hydraulic clutch KTM's and have never had a single problem.
Tools are made to keep bikes in good shape,I use em.
1. As I said, I would like the option for a cable-actuated clutch on KTMs. On longer rides, an extra clutch cable is usually packed.

2. Even with proper maintenance, the slave can go. Often there is no warning, and as you know it's not an easy trailside fix. Something as simple as actuating a clutch should not end a ride.

3. Fellow thumper viewers might be getting a kick out of my butting heads over KTM, with me actually bashing the KTM, but I've always thought the hydraulic clutch was a bit of a weak spot. YMMV.

Hey, I'd still buy another in a heartbeat. Just something to keep a close eye on, like the air filter and kickstand.
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Old 03-05-2013, 09:27 PM   #10
Foot dragger
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Originally Posted by Off the grid View Post
1. As I said, I would like the option for a cable-actuated clutch on KTMs. On longer rides, an extra clutch cable is usually packed.

2. Even with proper maintenance, the slave can go. Often there is no warning, and as you know it's not an easy trailside fix. Something as simple as actuating a clutch should not end a ride.

3. Fellow thumper viewers might be getting a kick out of my butting heads over KTM, with me actually bashing the KTM, but I've always thought the hydraulic clutch was a bit of a weak spot. YMMV.

Hey, I'd still buy another in a heartbeat. Just something to keep a close eye on, like the air filter and kickstand.
I guess they can fail like anything else but every time I ride a dirt bike with an old fashioned clutch cable .......it just feels like an antique after years on a KTM.
Trailriding anyway,clutch gets hot,adjustment changes and needs to be futzed with.

With the hydraulic actuation it takes care of itself always,and the pull is always smooth with no cable lubing. It just works.
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Old 03-05-2013, 10:26 PM   #11
Off the grid
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Originally Posted by Foot dragger View Post
I guess they can fail like anything else but every time I ride a dirt bike with an old fashioned clutch cable .......it just feels like an antique after years on a KTM.
Trailriding anyway,clutch gets hot,adjustment changes and needs to be futzed with.

With the hydraulic actuation it takes care of itself always,and the pull is always smooth with no cable lubing. It just works.
Hey, no way can I argue with how it feels. I just don't think it's needed or at least should be optional for 95% of KTM riders who are recreational.

Considering it's my only real complaint about the RFS bikes, I'd say it's doing ok, and my opinion is just one man anyway.

2 years I wailed on that bike, and only had 2 failures....the slave cylinder and a bad Pulsar coil. Considering how absolutely sick the bike is, that's minor in my mind. (about 80 bucks and 2hrs to fix both, combined)
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