2 - | Hydraulic clutch control

1 | Clutch master cylinder

2 | Inspection plug (replacement part)

3 | Lever pivot pin

4 | Lever with grub screw

5 | Fluid reservoir cover

6 | Clutch hose

7 | Mounting clamp

8 | Sealing washer

9 | Banjo bolt

10 | Fitting

11 | Bleed valve

12 | Dust cap

13 | O-ring

14 | Clutch slave cylinder

15 | Screw

16 | Clutch pushrod

17 | O-ring

18 | Microswitch

19 | Washer

20 | Rubber

21 | Guide

22 | Screw

Parts catalogue

Clutch
Clutch control

Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the clutch master cylinder assembly
Warning
The clutch master cylinder manufacturer advises against servicing of the clutch master cylinder (1) due to the safety-critical nature of this component. Incorrect overhaul of this component could endanger rider safety.
Maintenance operations of the master cylinder are limited to replacing the following parts: control lever, reservoir unit, and master cylinder fasteners.

Operation | Section reference
Drain the clutch system | D 4, Draining the clutch hydraulic circuit
Remove the LH mirror | E 1, Removal of the rear-view mirrors

Unscrew the banjo bolt (9) recovering the sealing washers (8), to release the clutch master cylinder assembly (1) from the clutch control hose (6).
Unscrew the two clamp screws (7) securing the clutch master cylinder assembly to the handlebar.
Remove the clutch master cylinder assembly (1). to dismantle the assembly, refer to the exploded view diagram at the beginning of the chapter.
Refitting the clutch master cylinder assembly
Position the clutch master cylinder assembly (1) so that the line of the gasket (A) between the clamp and cylinder is aligned with the punch mark (B) on the handlebar.
Tighten the retaining screws (7) to the specified torque (Sect. C 3, Frame torque settings), in the sequence 1-2-1, starting with the uppermost screw.
Locate the hose (6) and sealing washers (8) on the master cylinder (1) and secure with the banjo bolt (9), but do not tighten at this stage.
Warning
An incorrectly positioned hose can cause clutch faults and interfere with moving parts.
For the positioning of the clutch hose (6) and retaining clips, see the illustration at the end of this section.
Locate the hose (6) as shown in the figure, then tighten down the banjo bolt (9) to the specified torque (Sect. C 3, Frame torque settings).

Operation | Section reference
Fill the clutch system with fluid | D 4, Filling the clutch circuit
Refit the LH mirror | E 1, Refitting the rearview mirrors

Removal of the clutch slave cylinder
Warning
The manufacturer of the clutch slave cylinder (14) advises against servicing of its internal parts due to the safety-critical nature of this component.
Incorrect overhaul of these critical safety components can endanger rider and passenger safety.
The only components that should be renewed are the complete clutch slave unit, the bleed valve, the seals and the complete clutch pushrod assembly.

Operation | Section reference
Drain the clutch system | D 4, Draining the clutch hydraulic circuit

Undo the three screws (15) securing the clutch slave cylinder (14) to the engine and withdraw the unit from the crankcase.
Remove the dust cap (12) and the bleed valve (11) and unscrew the banjo bolt (10), taking care to recover the sealing washers (8): the unit (14) is now disconnected from hose (6).
Push in the piston to force out all the fluid from inside the cap.
The clutch pushrod (16) can now be removed. Inspect both O-rings (17) for signs of damage or deterioration and renew them if necessary.
Refitting the clutch slave cylinder
Grease and refit the clutch pushrod (16) with the two O-rings (17).
Locate the slave cylinder unit (14) in the crankcase and tighten the screws (15) to the specified torque (Sect. C 3, Frame torque settings).
Locate the hose (6) on the slave cylinder (14), ensuring that the hose end fitting is correctly positioned relative to the slave cylinder (14).
Warning
An incorrectly positioned hose can cause clutch faults and interfere with moving parts.
Locate the two sealing washers (8) and tighten the banjo bolt (10) to the specified torque (Sect. C 3, Frame torque settings).
Refit the bleed valve (11) and the dust cap (12).
Refer to the diagram on the following page for correct positioning of the hose retaining clips (6).

Operation | Section reference
Fill the clutch system with fluid | D 4, Filling the clutch circuit

Positioning of the clutch hose