bob Posted March 15, 2005 Report Share Posted March 15, 2005 Hi everybody. This may have been touvhed upon before, but i have not experienced it before so I don't have a clue what to search for. I have a 2003 rev3 200. The bike is going fine but recently my clutch lever has started weeping some hydraulic oil from a tear in the rubber boot ting which looks to seal the piston. I would like to fix this as stuff like this irratates me loads. I think that it is the standard AJP lever but am not sure, I will chect tomorrow. Is there an o'ring which seals the master cylinder?? To change it where can I get one and how do I change it? Can I just remove the lever and pull the piston out of the cylinder? Any help would be good. My local dealer does not seem to understand much I say so any other proper names of parts would be helpful. Thanks in advance! Bob Quote Link to comment Share on other sites More sharing options...
rlracer Posted March 15, 2005 Report Share Posted March 15, 2005 Have your dealer get a rebuild kit for your clutch master cylinder. It's easy to install. I'm shotting from the hip here. 1. Take the lever off 2. Take the master cylinder off the handle bar, hold it up right- so you don't drain the fluid. 3. Take the rubber boot off you will see a circlip- remove & install the new parts. 4.Re- install in reverse order. 5. Pull the cap off the master cylinder, add fluid, tap the clutch lever back a few times this should remove any air. 6. Smile and enjoy your Beta If I missed something i'm sure someone will chime in. Quote Link to comment Share on other sites More sharing options...
bob Posted March 15, 2005 Author Report Share Posted March 15, 2005 Sounds a little too easy! Thanks though. I will have a bash at it and if the worst should happen then i will have to get someone else to do it. I think that I will completely bleed my clutch aswell as it may have more air in it which could be causing it to drag. Thanks alot. Bob Quote Link to comment Share on other sites More sharing options...
digger Posted March 15, 2005 Report Share Posted March 15, 2005 1) order new piston with all new seals on, from main dealer for clutch master cylinder (about Quote Link to comment Share on other sites More sharing options...
bob Posted March 15, 2005 Author Report Share Posted March 15, 2005 Sounds simple enough, I will need to get a dust seal too right? Thanks. Quote Link to comment Share on other sites More sharing options...
lineaway Posted March 15, 2005 Report Share Posted March 15, 2005 New dust seal comes with the kit! It is as simple as it seems, just need snap ring pliers. Quote Link to comment Share on other sites More sharing options...
bob Posted March 19, 2005 Author Report Share Posted March 19, 2005 Thanks for your advice, I did it this morning. It was really simple and hasn't cost me anything yet. Big thumbs up to feetup Trialsport near Scarborough. They trusted me to pick up the part at 11pm from their fromt door when nobody was in and would let me pay for it next time I am their way, just so I could get going for the weekend. Cost Quote Link to comment Share on other sites More sharing options...
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