2 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
 Spare parts catalogue
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.
 
Unscrew the banjo bolt (16) collecting the gaskets (17), to release the clutch master cylinder unit (1) from the clutch control pipe (6).
Unscrew the two clamp screws (19) securing the clutch master cylinder assembly to the handlebar.
Refer to the exploded view at the beginning of this section for indications on disassembly and replacement of the master cylinder components.
Refitting the clutch master cylinder assembly
Insert the clutch master cylinder unit (1) on the left side of the handlebar to bring the terminal internal edge in correspondence to the bolted joints (A).
Tighten the fixing screws (19) to the specified torque (Sect. C 3, Frame torque settings) following the sequence 1-2-1 starting from the upper screw.
Locate the pipe (6) and gaskets (17) on the master cylinder unit (1) and secure with the banjo bolt (16), 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.
Orientate the pipe (6) as illustrated in the figure and then tighten the banjo bolt (16) to the specified tightening torque (Sect. C 3, Frame torque settings).
 
Removal of the clutch slave cylinder
Warning
The clutch slave cylinder manufacturer advises against servicing of internal components of clutch transmission unit (23) 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 transmission unit, the bleed valve, the seals and the com­plete clutch pushrod assembly.
 
Undo the three screws (24) securing the transmission unit (23) to the engine and withdraw the unit from the crankcase.
Remove the dust gaiter (4) and the bleed valve (3) and unscrew the screw (5), taking care to recover the gaskets (17): the unit (23) is now disconnected from the pipe (6).
Push in the piston to force out all the fluid from inside the cap.
At this point, it is possible to slide also the clutch gear rod (27). Check the wear state of the two O-rings (26) and replace them, if necessary.
Note
If the two O-rings (26) need to be replaced, it is necessary to replace also the O-ring (25) of the unit (23).
Refitting the clutch slave cylinder
Note
If the clutch pushrod (27) is replaced, it is necessary also to replace the O-rings (26) and (25) of the unit (23).
 
Grease and refit the clutch pushrod (27) with the two O-rings (26).
Note
If the unit (23) is replaced, it is necessary also replace the O-ring (25) and the two O-rings (26) of the pushrod (27).
 
Fit the clutch transmission unit (23) on the crankcase, tightening the screws (24) to the specified torque (Sect. C 3, Frame torque settings).
Locate the pipe (6) on the clutch slave cylinder (23), paying attention to the pipe retainer direction in the unit (23).
Warning
An incorrectly positioned hose can cause clutch faults and interfere with moving parts.
Position the two gaskets (17) and tighten the screw (5) to the specified torque (Sect. C 3, Frame torque settings).
Refit the bleed valve (3) and the dust gaiter (4).
To position the pipe retaining clamps (6) refer to the table on the following page.
 
Positioning of the clutch hose