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Thread: 1150 GSA Clutch Release Cylinder

  1. #1
    Rally Rat warthog's Avatar
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    Question 1150 GSA Clutch Release Cylinder

    I pulled my transmission to lube the splines and now that I have it mated it back up I'm installing the clutch release cylinder that I removed to get the transmission out.

    When I went to insert the cylinder but can't get it all the way in and I can't figure out why it is not going all the way in and I don't want to force it.

    Any ideas what is going on?


  2. #2
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    Been there....
    You need to re-align your clutch disk using a clutch alignment tool. I didn't have one and cobbled one together from a socket or something.

    Edit:

    On second thought...you don't mention that the transmission was removed. So I'm guessing the clutch actuating rod isn't oriented correctly. Long end into engine, if I remember correctly.

  3. #3
    Pepperfool GSAddict's Avatar
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    Quote Originally Posted by Warthog View Post
    I pulled my transmission to lube the splines and now that I have it mated it back up I'm installing the clutch release cylinder that I removed to get the transmission out.

    When I went to insert the cylinder but can't get it all the way in and I can't figure out why it is not going all the way in and I don't want to force it.

    Any ideas what is going on?

    Before you go any further:
    1) lube the little bearing with Hi temp wheel bearing grease before reassembling (I have done this on 3 separate occasions and am still on my original slave - 236,000km) They have very minimal grease from the factory.
    2) strip back the foam cover of the supply fitting (bottom in your picture) so it does not touch the metal elbow (water will collect there from the other end) - they all rust there and the line will eventually spring a leak
    3) Are you sure you have the pushrod the right way around? The small end with the shoulder goes toward the back. If you still have problems make sure the clutch reservoir cover is off and a rag covers it (fluid will squirt back when you push)
    '
    Ufda happens..........

    It's all about the details.

  4. #4
    Rally Rat warthog's Avatar
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    GSAddict: Thanks for the info.

    1. I did not remove the pushrod, I left it in when I removed the transmission.
    2. Where is the the little bearing you mentioned.
    3. Yes I saw you post on stripping back the foam to check the metal connectos and plan on doing that as well.


    Don

  5. #5
    Pepperfool GSAddict's Avatar
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    Quote Originally Posted by Warthog View Post
    GSAddict: Thanks for the info.

    1. I did not remove the pushrod, I left it in when I removed the transmission.
    2. Where is the the little bearing you mentioned.
    3. Yes I saw you post on stripping back the foam to check the metal connectos and plan on doing that as well.


    Don
    2) Right on the end of the slave cylinder The pushrod tip goes into it.
    The pushrod spins when the engine runs. If the grease runs low or dries out, the bearing fails, the slave piston will turn and the whole assembly fails allowing brake fluid to migrate along the pushrod and eventually soaking the clutch plate.
    Newer model pushrods in late 01 & on had a felt ring to slow the brake fluid contamination down although the slave will still need replacing.
    '
    Ufda happens..........

    It's all about the details.

  6. #6
    Rally Rat
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    I've replaced my slave cylinder twice and I recall that there was some pressure exerted by the pushrod against the slave cylinder bearing as I pushed the cylinder all the way into the cavity in the rear of the transmission. I assume this is the pushrod partially compressing the clutch diaphragm spring and pushing the slave bearing backward. My clutch fluid lines were disconnected when I attached the slave cylinders. If yours are attached this may produce a greater resistance to any movement in the slave cylinder bearing???

  7. #7
    Pepperfool GSAddict's Avatar
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    Quote Originally Posted by PETDOC View Post
    I've replaced my slave cylinder twice and I recall that there was some pressure exerted by the pushrod against the slave cylinder bearing as I pushed the cylinder all the way into the cavity in the rear of the transmission. I assume this is the pushrod partially compressing the clutch diaphragm spring and pushing the slave bearing backward. My clutch fluid lines were disconnected when I attached the slave cylinders. If yours are attached this may produce a greater resistance to any movement in the slave cylinder bearing???
    The pushrod is moving the slave piston back against a internal spring, that is what you felt. There is no way you have the strength to partially compress the clutch diaphragm, nor would you want to.
    '
    Ufda happens..........

    It's all about the details.

  8. #8
    Rally Rat warthog's Avatar
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    Tried the grease on the bearing and it's still not seating. Wondering if I've got an alignment problem.

  9. #9
    Pepperfool GSAddict's Avatar
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    OK this is the best picture I have of how far in the pushrod needs to go in (sorry this was a failed slave document picture)
    Does the pushrod go in this deep?

    '
    Ufda happens..........

    It's all about the details.

  10. #10
    Rally Rat warthog's Avatar
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    Here is a pic of how far in the push rod is in. I appreciate all the assistance. I'm getting ready to have surgery on my arm next week and I'm trying to get this buttoned up be for the surgery.


  11. #11
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    Quote Originally Posted by Warthog View Post
    Here is a pic of how far in the push rod is in. I appreciate all the assistance. I'm getting ready to have surgery on my arm next week and I'm trying to get this buttoned up be for the surgery.

    The pushrod looks like it's far enough in.
    Are you sure you are not hydraulicing the slave?
    Take off 1 of the lines and see if it will go in. The slave should push back with its own internal spring but firm hand pressure will overcome it.Then bleed the system.
    '
    Ufda happens..........

    It's all about the details.

  12. #12
    Benchwrenching PGlaves's Avatar
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    Open the bleed valve and wrap it so a little fluid won't ruin anything. Then put the slave cylinder in place and push it forward. Install little bolts.
    Paul Glaves - "Big Bend", Texas U.S.A
    "The greatest challenge to any thinker is stating the problem in a way that will allow a solution." - Bertrand Russell
    http://www.bigbend.net/users/glaves

  13. #13
    Aspiring Profligate jeff488's Avatar
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    Jeez, Paul.
    The simplicity of your reply is elegant.
    Don't get a big head,though.
    Jeff
    '04 Silver R1150RT "Big Oel". '05 Yellow KLR 650
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    "I just want somewhere to ride and food when I get there."

  14. #14
    Rally Rat warthog's Avatar
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    Mission accomplished...thanks guys.

  15. #15
    Pepperfool GSAddict's Avatar
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    Quote Originally Posted by Warthog View Post
    Mission accomplished...thanks guys.
    Whoa there! Not so fast. What was the problem in the end?
    '
    Ufda happens..........

    It's all about the details.

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