Questionthe bike was nocked over by a little kid broke the clutch handle replaced the handle but when replacing the handle the plunger came out of the resivoir and i can get it to bleed out i dont know if there is a specific way or if the resivoir is no good any suggestions?
AnswerWilliam, The only way the clutch master cylinder plunger can come out is if the snap ring breaks, rusts through or isn't installed properly. At 27 years of age, the hydraulic system needs to be disassembled, cleaned inspected and new kits installed for maximum function and safety.
Take the master cylinder apart, clean it real well and inspect the piston bore inside for signs of corrosion damage. If the cylinder bore isn't smooth and round, then the cylinder needs to be replaced.
If it cleans up okay, then you can put in a new kit. Bleed the master cylinder on the bench, so you know that it is pumping up some pressure. Transfer it to the bike, mount it so the fluid level is going to be horizontal, then tighten all the fittings. If you have a vacuum pump, you can suck the fluid down through the master cylinder and slave cylinder on the motor. If not pump the system out with the master cylinder at the bottom, then work your way back towards the top, opening and bleeding each fitting, until you get to the hose fitting at the master cylinder. Usually the air bubbles in the system will work their way up to that point and when you crack that fitting a few times, the fluid pressure should start building back up.
Because of all the kinks in the fluid lines, motorcycle hydraulics are very challenging to purge of air, but with patience, thought and plenty of fluid, you will prevail.
Bill Silver
