Clutch adjustment?

[Fire-medic]

I'd say you need to change your brake fluid In the entire clutch hydraulic system which of course includes a good bleed. You may have a leak somewhere or other which will of course need to be fixed 1st. Try changing the fluid and see how long it lasts before the lever comes back close to the handlebar

 

[Drifter2406]

Thanks for the reply, yes that what I was going to try first, I checked for leaks and cannot see any and the fluid does not look like it's going down but I only noticed it today.

 

[Fire-medic]

An internal leak of the master cyl can do that. Also put a paper bag cut-open below the left footpeg area, and just inboard of it, below the engine middle cover. That's the area below the slave cyl. You want to look for any leakage below it.

 

[Jack Hammer]

Is the master cylinder original? Sounds almost like you having a bigger bore cylinder thus moving too much fluid per stroke.

 

[Drifter2406]

Is the master cylinder original? Sounds almost like you having a bigger bore cylinder thus moving too much fluid per stroke.

Think so, haven't had the bike long but everything looks standard on the bike.

 

[Jack Hammer]

If I recall correctly, there are different Yamaha specific parts from other models that fit like factory but have different qualities, like light switch and otherwise. Who knows if someone threw incorrect parts at your bike when putting it together.

If your clutch were leaking, then it would cause clutch drag because the hydro side is not able to release the clutch due to lack of travel and you would see a leak. If your master were leaking, it would also manifest a shorter hydraulic throw. Your problem is opposite to that.

I'm not saying I'm right but I sure would check it out if I had the right master cyl.

 

[Fire-medic]

The cast-in bore size for both master cyl's is 5/8". Look on the bottom of the master cyl.

 

[Drifter2406]

Thanks for the reply guys, I have ordered a rebuild kit in the 5/8 so when that arrives i will strip it and have a look, I will keep you all posted.

 

[Fire-medic]

You might want to pull your left middle engine cover, and take a look at your slave cyl. With the bike upright, as it would be on the centerstand, you won't lose hardly any oil, if your slave cyl looks like this crusty one on the left, time for a rebuild or replacement (right one).

 

[Drifter2406]

You might want to pull your left middle engine cover, and take a look at your slave cyl. With the bike upright, as it would be on the centerstand, you won't lose hardly any oil, if your slave cyl looks like this crusty one on the left, time for a rebuild or replacement (right one).

View attachment 85878

Thanks for the comparison, I have bought a kit for the Master but I wanted to replace the slave with a complete new unit but I cannot find anything other than kits.

 

[Jack Hammer]

There is nothing wrong with the kits. Just clean the bore good with scotchbrite. Lube the rubber and install. Use oem spring instead of the the one in the kit. The kit spring is softer.

 

[Fire-medic]

When you disassemble the slave cylinder you'll be able to see if it has pitting on either the female side or the piston sufficient to cause issues with it leaking over time. I use Sean Morley, captain Kyle, or Ron Ayres Yamaha for parts

 

[Jack Hammer]

Discoloring does not matter. Deep cavities do. Very minor ones not.

 

[Drifter2406]

When you disassemble the slave cylinder you'll be able to see if it has pitting on either the female side or the piston sufficient to cause issues with it leaking over time. I use Sean Morley, captain Kyle, or Ron Ayres Yamaha for parts

Thanks for the info, as for dealers i'm in the UK. The kits over here are about £20

 

[Drifter2406]

I have been looking at the parts etc, does anyone know what the difference is between the 2003 model and the 2004 as most of the parts only go up to 2003 but do note state the 2004 anniversary which mine is? not that the anniversary means anything just that it has to be after 2004.

 

[Fire-medic]

Same parts for all Gen I's. The '85 first year slave cyl will fit a last-year 2007. The twentieth anniversary year is 2005 as the first year is 1985.

There should be a numbered plate above the engine, this one is missing.

 

[Jack Hammer]

Your local Yamaha dealer should carry new slave and rebuild kit. Motorcycle parts suppliers carry only kits.

 

[Drifter2406]

Same parts for all Gen I's. The '85 first year slave cyl will fit a last-year 2007. The twentieth anniversary year is 2005 as the first year is 1985.View attachment 85884

There should be a numbered plate above the engine, this one is missing.

Yeh mine is 317 of 2000

 

[Incider]

Thanks for the comparison, I have bought a kit for the Master but I wanted to replace the slave with a complete new unit but I cannot find anything other than kits.

I got a new cylinder a couple of months ago from fowlers in Bristol. £132 and overnight delivery. Just rebuilt the old cylinder ready to do a straight swap onto my other max

 

[Incider]

I got a new cylinder a couple of months ago from fowlers in Bristol. £132 and overnight delivery. Just rebuilt the old cylinder ready to do a straight swap onto my other max

And don't forget to order a gasket