ec300 clutch problem

[dirtjunky_uk]

hi ive got an ec300 03 model and it stalls when put into gear,ive blead the clutch (back blead with syringe) fresh dot 4 fluid still no change also checked lever free play,so today i pulled the plates out and they look good no warpage,basket looks good no grooves,anyone got any ideas on what to check next also running on rock oil gro

 

[rpduc]

Slave cylinder seals?? Still have some air bubbles?

There might be something down a ways in this thread for you...

http://www.gasgasrider.org/forum/showthread.php?t=3421&highlight=slave

Or search "slave" for more threads.

 

[dirtjunky_uk]

thanks,no air bubbles in the system ive checked and double checked,now the slave cylinder are the seals easy to change,can anyone give me some advice on doing it as ive never had one apart cheers adam

 

[seitz64]

ec300clutch

hi i think its time to overhaul both clutch master & slave cyl also check the push rod from slave cyl to clutch pressure plate for wear good luck

 

[dirtjunky_uk]

yea think im going to have to drop it into the mechanic,i cant find anything online the manual i downloaded would make good toilet paper,thats about it,plus ive never opened up a master cylinder or slave cylinder before

 

[HydroDog]

Did you just start having problems with it or has it been getting worse?

 

[iancp5]

Have you checked if the problem is lack of movement of the push rod? Is it actually moving much when you operate the clutch. I.e. is it drag because something's wrong in the basket or are the hydraulics just not working. Also I saw a bent pushrod once so maybe check it's nice and straight.

Also I assume the plates are not new? If they are they can sometimes be a bit weird for a while until they bed in.

 

[dirtjunky_uk]

no not new plates,i never checked the pushrod to be honest with you,(ill do that today)and the problem has only just started,to the point i cant ride the bike at all

 

[iancp5]

If it just started with no change from yourself then you'll just have to work your way through the system trying to see which bit isn't working as it should. I think there's a fair chance it's not the gubbins in the clutch basket, plates etc or you'd see the wear marks or plates would be out of spec. Worth checking nothing's come loose or out of place so that the pushrod is actually pushing the clutch apart as it should. They don't move very much so just a little problem could cause it not to work.

 

[dirtjunky_uk]

thanks ian yes the pushrod is pushing the basket out but only say half an inch or so.i got a mechanic just up the road from me who knows his stuff so its going up there in the morning ill post the outcome when i find it just for other users refrence

 

[dirtjunky_uk]

right i did not want to admit defeat on this as ive rebuilt 2 and 4 stroke motors,so i thought how hard could it be to strip a slave cylinder,well could not of been easier and to my joy i found a worn o ring on the piston

 

[iancp5]

right i did not want to admit defeat on this as ive rebuilt 2 and 4 stroke motors,so i thought how hard could it be to strip a slave cylinder,well could not of been easier and to my joy i found a worn o ring on the piston

Having just acquired a new (secondhand) GG I seem to have a similar problem! I'll make sure I check the slave first. How did he manage for it to test ride perfectly?

 

[dirtjunky_uk]

well ian i brought the bike over the net,on the trust of the seller over the phone he arranged it to be delivered to me (know why now) because it tuned up with teeth broken off both sprockets a chain that was so worn out it was hard to belive and a clutch that never worked,a hard lesson learned for me

 

[iancp5]

well ian i brought the bike over the net,on the trust of the seller over the phone he arranged it to be delivered to me (know why now) because it tuned up with teeth broken off both sprockets a chain that was so worn out it was hard to belive and a clutch that never worked,a hard lesson learned for me

Actually I was referring to my seller!

I test rode it and the clutch worked fine. Got the bike off the trailer at home and it was playing up. Had a quick chat with Dave at BikeTech and he advised me to check a few things before rebuilding slave and masters.