Motorcycle Repair: Clutch replacement issue, suzuki bandit 1200, clutch slave cylinder

Question
Replaced clutch on 2000 Suzuki Bandit 1200.  Got the basket back in, and before I got the circlip (it was hiding)back on, I (like an idiot) decided to see how much more pull was needed with the new springs.  I pulled the clutch lever, and heard a "ping"... it shot out the rod from the center of the shaft that the basket sits on.  Now I cannot get that rod pushed back into the shaft.  I figured I did some kind of damage to the clutch slave plunger, but I can't get the slave off the sprocket cover.  Looks like just 2 bolts holding it on.  What have I done?

Answer
Hi Erik,

I did almost the same thing with front
brakes one time. I pulled the lever
when the wheel was off and the
brake piston went flying.
What a pain!

From what you described I think the
clutch slave cylinder piston has moved
out of place. This means because
you had no pressure against it or the
push rod in it's center the piston
has moved out further than it should have.

There are two ways to fix this.

One way might be to open the bleeder
screw on the slave cylinder and
try to push the rod and slave piston
back far enough to get the clutch assembled.

Of course fluid will come out so a small
hose in a jar might help.

Afterwards you would have to refill
the clutch fluid reservoir on the
clutch lever to prevent air from getting
into the lines.

The second way is to get the slave cylinder
off and clean and reassemble it.
Push the piston back all the way in
and then bleed the air out
of the lines again when it is installed.

If you try the first method and the rod
or piston will not go back in then
it may be out of place and you
may have to remove the slave anyway.

With the bleeder open the piston should
go back in if you can put some
pressure on the push rod.

If you see any leaks then the piston may
have popped out if that is even possible
with it bolted on the bike.

So to sum up, put the clutch rod back in
and push on it with the slave bleeder
open and attached to a small hose
or wrap it with a rag to catch the
fluid drips.

The rod and slave piston should move
unless something is badly out of place.
Then you will need to remove the
slave. If it has phillips screws
you will need a hand impact driver
for the screws.

IMAGE:
http://partstream.arinet.com/Image?arik=RoBpTcK5IiLPeusU7XbM&arib=SUZ&arim=pV1Md...

Remember to add fluid to the clutch master cylinder
if you drain any fluid from the slave.

Good luck!
Wayne S.
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