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2004 fireblade clutch issue

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badapple View Drop Down
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    Posted: 08 Oct 2019 at 20:50
Hoping you clever lot can shed some light on a problem a friend has.

Similar clutch set up to the ape, hydraulic clutch , we've bleed it through using various methods but can't get a good feel on the lever but that's not the real problem. When we pull the clutch in to bleed it fluid spurts out of the resivoir at an alarming rate! Ive never seen this before on any bike and have no idea what's going on. He's bought a rebuild kit for the master cylinder but I'm not convinced that is the problem but to be honest I haven't got a clue what it could be. I've taken the slave off to have a look as well as the master cylinder and it all appeared to be as it should however he said it was fine until he changed the front sprocket and had to remove the slave for access, again that seems odd but he's a decent car mechanic but this is his first bike. Fluid has also gone black within a hundred miles as he's still using it daily as it rides ok. 

Anyone owned one of these blades or seen this problem before, he's not exactly loving life on two wheels as he's had a lot of trouble with the bike already. 

Any words of wisdom gratefully received. 
I started out with nothing and I've still got most of it left
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legend88 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote legend88 Quote  Post ReplyReply Direct Link To This Post Posted: 08 Oct 2019 at 20:56
Pressure must be getting past the seals in the master cylinder if it's pressuring the reservoir. Also check the reservoir diaphragm isn't damaged.

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badapple View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 08 Oct 2019 at 21:49
Originally posted by legend88 legend88 wrote:

Pressure must be getting past the seals in the master cylinder if it's pressuring the reservoir. Also check the reservoir diaphragm isn't damaged.


Nice one so a rebuild kit could be the ticket, I'm seeing him tomorrow to lend some tools so I'll have a look at it again cheers. 
I started out with nothing and I've still got most of it left
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Pete 86 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Pete 86 Quote  Post ReplyReply Direct Link To This Post Posted: 01 Jan 2020 at 11:46
Some kawasakis do this too.   So im not sure its a problem although it might be.  You have to operate the clutch slowly when bleeding. This way it shouldnt squirt out of the reservoir. 
Try cutting some cardboard or summet to fit in the master and sit it in whilst bleeding some kwaks have a plate in to prevent just that.  Obviously take the card out when its bleed eh.
Also try gravity bleed it. Crack the slave and let it run.
You can also wrap a elastic band round the clutch overnight keep it pulled keep the pressure on the slave piston if it sticks.  Re-square it in the slave body.  

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Stevex View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevex Quote  Post ReplyReply Direct Link To This Post Posted: 01 Jan 2020 at 15:14
On various master cylinders of bike brake systems I've bled in the past, if I've pulled the lever too quickly I get a fountain of fluid with cap and diaphragm removed. I learnt that early on and now squeeze the lever slow time and even then you need to be careful.
The clue appears to be in the work just done...is it a coincidence that it worked fine until he disturbed the slave?
I take it the system is properly bled, slave unbolted and held as high as possible? It only takes a couple of small bubbles of air to give the symptoms you have described.
Also, sucking eggs and all that, but does it have a mc bleed nipple? Has it been cracked and bled?
People say I don't know Jack Sh1t; but I do, he lives next door.
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badapple View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badapple Quote  Post ReplyReply Direct Link To This Post Posted: 02 Jan 2020 at 14:54
Sorry gents should of updated the thread. We rebuilt the master cylinder with a new kit and it solved the problem. 
I started out with nothing and I've still got most of it left
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legend88 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote legend88 Quote  Post ReplyReply Direct Link To This Post Posted: 02 Jan 2020 at 23:29
Good Job!

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