Hi everyone! I’m having a clutch issue with my FE 450 2023. I previously took it to House of Motorrad, and they suggested a solution using a rebuild kit. Unfortunately, I’m still experiencing the same clutch problem. Does anyone know of a motorcycle shop in Boulder that’s open and specializes in motorcycles or enduro bikes? I’ve tried going back to House of Motorrad, but it seems to be temporarily closed. I’d rather not leave this issue unresolved until the riding season starts again. Thanks!
Not in Boulder. Personally have not had great experience with HofM on my bike. Good people, just didn’t really solve the issue. I have been working with Mike @ Motorsport Masters in Wheatridge and they have been excellent.
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What is the issue?
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Thank you so much, Chris! My only issue with Motorsports Masters is that I don’t have a car or a way to transport the bike there from Boulder.
The problem is that the clutch isn’t disengaging properly — when I’m stopped, the bike wants to creep forward, and the gear changes are usually rough.
This what they told me at HoM when I brought the bike back in September: The slave cylinder has been unbolted from the bike at least once since the bike was new. When it was reinstalled, the gasket was poorly fitted and folded over, leading to it shearing off. The rubber seal has a chunk taken out of it too. Likely because slave cylinder was improperly installed (maybe in an attempt to bleed the clutch?)
So you brought it in, they diagnosed it per you post, did a rebuild kit and it still has the issue? Have you tried bleeding the clutch?
Yes, I brought it in, installed a rebuild kit, and also bled the clutch. They told me to ride it for a while since the issue might or might not be fully resolved. The bike felt fine on the first few rides, but now the problem has come back.
Sounds like air has gotten into it. I’d bleed it again myself
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Motorsport Masters as Chris mentioned are the go-to, especially for singles. The owner was a KTM Baja team mechanic for a decade+.
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Thank you so much for the advice!
Thank you so much! I think I’ll bring the bike to their shop
Did your slave cylinder piston get changed (23 diagram below) with the rebuild kit or just the gasket and outer o ring (20, 21)? Sounds like you are loosing fluid or getting air in the system and that is typically caused by the piston seal. The piston/seal itself has a new updated part number.
When rebuilding the stock unit it needs a new piston in addition to the outer gasket and o ring. The stock unit has very narrow pistons at the sealing surface which allows for distortion when they get hot, in general that leads to shorter seal life and leaks. They are easy to rebuild but you need to take care in keeping the piston perpendicular to the bore when it is being pushed back into the cylinder so as not to damage the new seal. Slavens racing has the rebuild kit that includes a new piston.
I’d suggest replacing the stock part with an aftermarket billet clutch slave cylinder from Rekluse or Oberon. It will yield an upgrade in seal life and performance/clutch feel.
The clutch must be bled with the slave cylinder fully bolted to the engine case, and it should be bled backwards by pushing fluid from the slave cylinder to the master cylinder. Also use the correct hydraulic fluid noted on the master cylinder cap. Brembo uses DOT4, Magura uses Mineral Oil.
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Jason, thanks a lot for all the info, I really appreciate you taking the time to explain everything!
To answer your question: the piston was replaced with the rebuild kit.
I’m also seriously considering upgrading to a Rekluse or Oberon billet slave at this point. I’ll bring it to Motorsport Masters to check as well!
Thanks again, super helpful!!
You’re welcome. Good luck. It is far more rare to have air intrusion at the master cylinder, but that can be rebuilt too with a new piston, seals and spring. Complete kits are available.
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Thank you so much Jason! Sorry for the late response!
This also sounds like it could be warped clutch plates. Definitely continue with purging the hydraulic clutch as that’s an easier/cheaper fix, but if still no luck, could be the metal clutch plates are warped.
The bike is at Motorsport Masters right now and they’re fixing the issue. They found some silicone in the master cylinder, which likely got in there from a crash I had. That could explain the clutch acting up. They’re taking care of it, so hopefully that resolves everything!
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