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Discussion Starter #1
just fitted a new clutch to my 00 K1200RS, all went in fine, just fitted gearbox back in and put slave cyl on and bled clutch system, all seemed fine so i locked up bleed nipple then pulled clutch lever a few times and....LOCK.....its locked solid....lever won't pull in at all????

please help guys
 

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How far did you get on replacing parts after you installed the tranny and clutch slave?
Do you still have the crossmember off?
so you can get to the clutch slave cyl?
 

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Discussion Starter #3
no i had just put slave on, didnt wanna rebuild it at all before i had a working clutch, i popped the slave cyl back off and the insides of the slave cylinder are apart, spring is still in slave but small rod and circlip are in the gearbox end of things???
 

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That's good.

The salve cylinders piston should be able to be pushed in by hand.
So when you are holding the slave and have a tool to push the slave cylinder piston in you should be able to retract the piston in the cylinder. It takes some force to do this.

can you push the piston in?

Then with the piston pushed in, pull on the clutch lever on the handle bars, slowly with very little pressure and the slave cylinder piston should move out.
Does it?
 

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Macker, I have to leave now for the day.

If the slave cylinder is working correctly with the last test, then in it's normal state the piston should be fully extended when at rest with the cylinder off the bike.

When you install the slave cylinder it should not be able to seat against the transmission unless you force it by hand and push it in colapsing the slave piston. This holds some pressure againts the clutch release push rod.

If you are able to place the slave against the transmission with-out any force you have something wrong inside the clutch or the wrong push rod.

Sorry I can't stay today to help more than this.

Barry
 

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Discussion Starter #6
cheers, yeh i did that, slave cyl feels like its working fine, i have noticed that the push rod is very difficult to get out, like impossible with my fingers but if i get a pliers onto it it will come out, its a brand new rod so its the correct one, i deffo lined the clutch plate up correctly but it does feel like something aint lined up inside????
 

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Did you install the push rod the right way round?

Ball end makes contact with the diaphragm.

Pointy end must be centred inside the thrust bearing in the slave.

As Bazra says, if the slave is free, something is wrong inside or binding up. You should be able to push/pull the pushrod with your fingers and hear a definite click as it comes to a stop against the diaphragm plate inside. It should also be possible to turn the pushrod with your fingers fairly easily. You can get oil down the hole (after a seal leak!) which can make the rod feel a but 'gummy', but it should be loose and free as there is a generous clearance of about 1/2mm

From memory, the pushrod sticks out so the slave once centred on the pushrod needs to be pulled down about 1/4-3/8" on the flange bolts to tension the diaphragm plate.



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