Clutch Refilling on a 696. Problems with pressurizing the circuit

Started by WetDuc, February 13, 2011, 05:32:59 PM

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WetDuc

So...one of the bikes went on a lowside on the left side (rider fine) and it's being revived.
The clutch master and lever was ruined and new OEM ones were installed, but when I try to bleed the system, I get nothing coming out the bleed valve.  A little bit of fluid comes out initally, but it stops coming out after a couple pumps of the lever and the fluid system just seems to stop pressurizing from the lever action, despite the lever going through it's full arc multiple times.  
Vapor lock?  Am I doing something obviously wrong and not realizing it? 
I tried removing the banjo at the slave cylinder, but still pumping does not even expel fluid from it and the level in the master cyclinder does not change.  I have two masters and neither is working.  I tried pumping one of the masters before installing it on the banjo and it expels fluid from the banjo bolt attachment, which is why I'm wondering if the hydraulic line could have been damaged from a pinch, but not show outward signs of the damage.  I don't see anything wrong with it.


I also tried forcing the clutch slave cylinder piston back into the housing (per service manual), but this also did not help with getting a successful bleed of the circuit.
I would really appreciate any help, guys.  We have been bringing the 696 back to life for the past two weeks, and this is the last hurdle to clear before she's back on the road.
Thanks
2007 S2R1000, 2009 M696 & 2008 M695 (foster bikes)

ducpainter

It's air.

When you have the system apart and dry, air is everywhere.

What I do, not owning a power bleeder, or a mityvac, is fill the master, open the bleeder (a line from the bleeder submerged in a jar of fluid helps), and keep the lever halfway back with tape or any convenient means.

Every now and again pull the lever to the bar. If you feel some resistance or see fluid...not air...entering the jar you can do the 'pump it up hold it down bit'.

Keep the reservoir full...it will take a bit of time and fluid.
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Raux

It took quite a while for me to get all the air out of mine as well... patience

WetDuc

Thanks for the suggestions!  I did notice yesterday that at one moment it seemed we were getting some air bubbles to come out of the bleeder valve.  It stopped coming out after a few pumps of the lever, but I will absolutely try again today and take more time to see if we have success.

If I can't get it to work the second time, are you suggesting I use a Mityvac or something like it and that should do the trick?  I was thinking that having a vacuum at the bleeder might suck out the air better than trying to pump it from the lever.

Right now, I've been using the one-man-bleeder I bought on monsterparts that works for all my hydraulic systems that are mostly full of fluid to begin with.

I will post up later today with the status of my problem.
2007 S2R1000, 2009 M696 & 2008 M695 (foster bikes)

Howie

Pumping s-l-o-w-l-y with the one man bleeder should eventually get you to where you are building pressure.  A vacuum bleeder will certainly speed things up and you will have the tool for future use.

WetDuc

Got it guys!  Just needed some extra love and patience.  THANKS!  ALL 3 bikes back on the road!
2007 S2R1000, 2009 M696 & 2008 M695 (foster bikes)