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"KRS/GT" Technical Q&A K1200RS/GT Technical Questions/Answers

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  #1  
Old 05-22-2018, 11:38 PM
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sbeast7 sbeast7 is offline
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Clutch lever has zero resistance

Went out to garage to juggle bikes so I could service one of them and my k1200rs clutch lever has no resistance when pulling it in. Thinking I'd mash gears and stall bike if I started it and tried to put it in gear I've not try to move it under power.

2004 K1200RS with ~15,000 miles

Checked fluid level in site glass when bars turned to right lock, looks full. Opened the master cylinder and same result, full of fluid, so does not look like any leaking, or if it is, its very slow / small leakage.

Pulled handle in very slowly 2 or 3 times and each time tiny bubbles came up from bottom if reservoir. Put top back on master cylinder. Located the bleed connection under right fairing and feels dry, no leakage apparent. Not seeing any fluids on floor under bike.

So, I am at a loss as to what to do next. Before I dig in to inspect the slave cylinder, what else can I do to troubleshoot and rule out everything EXCEPT the slave?

Any helpful instruction is welcome, and / or links to related threads as well.

This all happened out of the blue, bike was sitting for a couple of weekends but I had it out in late April and everything seemed fine. Don't think it matters buyt bike was services at MAX BMW for brake flush and oil change back in February.

Really hoping this is something simple but not obvious to my thick skull, really do not want to deal with a leaking slave and all that entails once the fluid makes its way down the actuator rod.

Help!
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  #2  
Old 05-22-2018, 11:50 PM
KafkaKaffe KafkaKaffe is offline
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Re: Clutch lever has zero resistance

gosh if there is air entering the system and no evident leaks a tthe master or near it then its down the line somewhere. Is it that hard to check the slave?

edit

wow that looks like an involved job theres a youtube vid of it being done but I dont envy your future.
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  #3  
Old 05-22-2018, 11:57 PM
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Re: Clutch lever has zero resistance

I would bleed the slave cylinder and see what happens. Very easy to do!
Since the fluid is not low, that could be a good sign that the slave is not leaking and maybe the master cylinder is shot? But I would bleed the system and maybe you’ll get lucky and all will be ok,
Did the dealer bleed the clutch as well? If they did maybe they injested some air in the system.
Bubbles are normal when pulling clutch in, in fact when you bleed the system put a quarter over the hole that the bubbles come out of so you get brake fluid squirting all over the place.
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  #4  
Old 05-23-2018, 09:07 AM
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Re: Clutch lever has zero resistance

Bubbles coming out of the MC pressure relief hole? The smaller hole?Not normal....fluid should come out of the hole as you release the clutch,not air bubbles.

So there is air in the system if "bubbles" are coming out.A quick way to remove some of that air is through the MC relief hole.Slowly pull in the clutch and slowly release.Wait a few seconds and do it again....and again until no tiny air bubbles come out.

Then bleed the whole system.Good luck if further inspection of the slave cylinder is required.Lots of parts have to come off the bike to even get the slave out of there.
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  #5  
Old 05-23-2018, 10:49 AM
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Re: Clutch lever has zero resistance

Agreed, but I'm assuming that as he pulled the lever in that it created such a squirt it may seem likes bubbles!
Everyone has a different perspective on what someone is trying to covey, this is why I keep telling myself to stop responding to these posts.
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  #6  
Old 05-23-2018, 01:00 PM
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Re: Clutch lever has zero resistance

Yes, but everyone's perspective helps zero in on the problem, maybe slowly though. Lack of detail is an issue too.
21 52 2 333 433 OUTPUT CYLINDER CLUTCH - $232.88
Effort to install, large.
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Old 05-23-2018, 04:14 PM
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Re: Clutch lever has zero resistance

BeemerBoneYard has an aftermarket slave for $109. Might be worth investigating.
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Old 05-23-2018, 11:06 PM
Lowndes Lowndes is offline
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Re: Clutch lever has zero resistance

Quote:
Originally Posted by bruincounselor
BeemerBoneYard has an aftermarket slave for $109. Might be worth investigating.

I've been using one of these for 4 months now, doing well so far.

+1 on what pbegin said, too, bleeding the clutch system to start with. There is a bleed valve on the end of a line from the slave cyl.

If the slave cyl seal failed, the fluid would come from a weep hole in the slave cyl housing or from the clutch, specifically the joint between the tranny and engine cases. No drips is a good sign.

If that slave seal failed, the DOT4 will destroy the tranny seal, too.

Hope it's real simple and a bleed cures it.
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Old 05-24-2018, 12:05 AM
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Re: Clutch lever has zero resistance

I think you have to drill the weep hole to have one. And you need a little "grub screw" (miniature bleed nipple) that screws into the bleed line when you remove the allen block screw. There is a check valve in there that needs the grub screw to turn it into a unit that works in reverse fashion to bleeding brake calipers. I do recommend reverse filling the unit if you replace it. Available from bmw oem'
I think this is it: 34 21 2 330 310 VENT SCREW - M10 (to 08/98)0.02 1 $12.97
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Last edited by Beech : 05-25-2018 at 12:40 AM.
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  #10  
Old 05-26-2018, 02:27 PM
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Re: Clutch lever has zero resistance

Good luck on the bleeding, I hope it works. When my slave went, it went on a trip and the fluid level in the reservoir definitely went down - and out the tranny seal and into the clutch housing area. Two hundred miles back home and it was slipping like crazy by the end and I went through an entire regular (small) size bottle of brake fluid. It did foul the clutch requiring the whole seal and clutch replacement and slave reseal process. Big job. BUT it never had time to seep out the mating surface between the trans and the bell housing, so, it might take a while to show there.... Took me two full weekends making sure I did it right. Took two 200 lb guys with a 4 ft extension to break free the 30 + mm fine threaded swingarm bolts that the dealer had apparently used a thread lock on at some point. The fluid that had pooled up came out when I split the trans from the bell housing.

Hopefully bleeding solves your problem....
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  #11  
Old 05-26-2018, 04:23 PM
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Re: Clutch lever has zero resistance

You gotta heat those swing arm journal bolts and lock washers with something hot, almost blistering the paint. I use a infrared thermo gun and propane torch or industrial hot air gun. It is possible to pull the aluminum threads from the drive shaft housing if things are tight. New from the factory they have a locking agent and most use blue loctite on them after that. Red will guaranty thread destruction (when in aluminum) if not heated!
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  #12  
Old 05-27-2018, 10:23 PM
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Re: Clutch lever has zero resistance

thanks for the comment folks .... So far I've tried to avoid dealing with bleeding brakes etc ...
was never very good at it when I was young trying to work on my own car ... and my bikes back then were all cables :-)

but I guess its time to deal with it ... I just ordered this vacuum bleeder on Amazon ...

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

also pulled the clutch bleed connection down from behind the fairing today ... looks like I need to get one of those bleed nipples to open the check valve in the factor fill adapter at the end of the bleed line ... will call a dealer Tuesday to order of of those ...

Hoping that since master cylinder fluid level seems fine, system needs to be bled or master cylinder is shot ... based on the complete lack of resistance in clutch lever I'm betting on need to rebuild master cylinder

will post back once bleed job is done
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  #13  
Old 05-27-2018, 11:56 PM
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Re: Clutch lever has zero resistance

There gotta be a member in the area that can give you a hand.?????
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  #14  
Old 05-28-2018, 09:05 AM
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Re: Clutch lever has zero resistance

Bleed nipple is a pretty standard 10mm bleeder.Same as the fronts on my car.

Like this:

https://www.dormanproducts.com/p-15399-13908.aspx

Any autoparts should stock that.
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2003 K1200 RS at 53 (Oh Yeah......over 6000RPM)
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Old 06-01-2018, 04:12 PM
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Re: Clutch lever has zero resistance

Yep, standard nipple, easy to replace when I did my clutch and slave job all those years ago
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