Clutch hydraulic control

2 -	Clutch hydraulic control

1	Clutch master cylinder

2

3	Bleed unit

4

5	Special screw

6	Clutch hose

7

8	Vibration-damping pad

9

10

11	Blanking plug

12	Complete brake fluid reservoir

13

14	Hose guide

15

16	Special screw

17

18

19	Microswitch

20	Clutch pushrod

21

22

23	Clutch transmission unit

24

25

26

27

Parts catalogue


1100	Clutch control
1100S	Clutch control

Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.

Removing the clutch master cylinder assembly

Critical safety components. The clutch master cylinder manufacturer recommends that you do not attempt to service the internal components of the clutch master cylinder (1). Incorrect overhaul of these critical safety components can endanger rider safety.

Only a limited number of master cylinder parts should be replaced, that is control lever, reservoir assembly and cylinder fasteners.


Operations	Reference - See Section
Drain the clutch circuit	D 4, Draining the clutch circuit
Remove the left hand guard/rear-view mirror assembly	E 1, Removing the hand guard - rear-view mirrors

Undo the special screw (16) -keep the gaskets (17)- to release the clutch cylinder assembly from the clutch control hose (6).

Undo the two screws (18) securing the clutch master cylinder unit (1) to the handlebar.

Remove the clutch cylinder assembly (1): please refer to exploded view diagram at the beginning of this section for clutch cylinder disassembly.

Refitting the clutch master cylinder assembly

Refit the complete clutch master cylinder unit (1) onto handlebar, use the pilot dowel to position it correctly.

Tighten the retaining screws (18) to the specified torque (Sect. C 3, Frame torque settings) working in a 1-2-1 sequence.

Route hose (6) onto clutch master cylinder unit, fit seals (17) and start the screws (16) in their thread.

Position the fitting as shown in the figures.

Incorrectly positioned hoses can cause faults and interfere with moving parts.

Tighten the screw (16) to the specified torque (Sect. C 3, Frame torque settings).


Operations	Reference - See Section
Fill the clutch system with fluid	D 4, Filling the clutch circuit
Refit the left hand guard/rear-view mirror assembly	E 1, Refitting the hand guard - rear-view mirrors

Removing the clutch transmission unit

Critical safety components. The clutch transmission unit manufacturer recommends that you do not attempt to service the internal components of the clutch transmission unit (23). Incorrect overhaul of these critical safety components can endanger rider safety.

Only a limited number of transmission unit parts should be replaced, that is bleed unit, seal and complete piston.


Operations	Reference - See Section
Drain the clutch circuit	D 4, Draining the clutch circuit
Remove the left fairing	E 2, Removing the side fairings

Undo the three screws (24) securing the clutch transmission unit (23) to the engine.

Remove the clutch transmission unit from the engine. Do not damage the O-ring (22).

Remove the cap (4) and drain (3), loosen screw (5), collect seals (17):

Push in the piston to expel all fluid inside the unit.

The clutch push-rod (20) can now be removed. Check both O-rings (22) for wear and replace, if necessary.

Refitting the clutch transmission assembly

Lubricate and refit the clutch pushrod (20) with both O-rings (22).

Lubricate the O-ring (22) and fit with the transmission unit (23) onto the casing.

Tighten the screws (24) to the specified torque (Sect. C 3, Engine torque settings).

Position the hose (6) onto the clutch transmission unit (23). Ensure the hose fitting is properly positioned onto the unit.

Incorrectly positioned hoses can cause faults and interfere with moving parts.

Position both seals (17) and tighten the screw to the specified torque (Sect. C 3, Engine torque settings).

Refit the bleeder and plug.

To position the clamps retaining the tube (6), please refer to the figures at the end of the section.


Operations	Reference - See Section
Fill the clutch system with fluid	D 4, Filling the clutch circuit
Refit the left fairing	E 2, Refitting the side fairings

Clutch hose routing