Join Date: Mar 2006
Location: Easton, PA, USA
clutch slave c-clip
I had a clutch failure on my '03 LT with just shy of 150K miles. Tonight I pulled the slave and found the c-clip that holds the plunger/bearing/spring assembly inside the slave had blown out and was laying in the access, resting on the clutch push-rod where the slave seats. As I pulled the slave off and the last screw was removed, it shot off like a rocket from the spring not being held in by the c-clip, releasing additional dot4 fluid. Having not been inside the bike here before, is the c-clip failure what caused the dot4 fluid to be introduced to the seal? Had that clip not come out, would the dot4 have remained behind the plunger assembly? Or, does the leaking o-ring allow the dot4 fluid to break down the metal material of the c-clip and it just eventually pops?
The night it failed, I was about 200 miles from home so I kept chugging since it was all interstate. I noticed a nasty smell of fluid burning (couldn't tell if it was trans or dot4) each time I was traveling up-hill, but the smell subsided considerably when I was on level ground or moving downhill. I plan to replace the entire clutch, clutch slave and trans seals but was looking for some validation on the smell. At this point, I'm unsure if it was dot4 or gear lube that screwed the clutch.