1999 Bandit 1200S - Clutch Release Cylinder Piston Seal Replacement

Автокөліктер мен көлік құралдары

In this video I replace the clutch cylinder seal and spring on my 1999 Suzuki Bandit 1200. The video covers removal, cleanup, re-installation and clutch bleeding.
0:00 Intro
0:39 Disassembly
1:54 Cleanup , part 1
2:28 Removing the slave cylinder
5:09 Cleanup, part 2
6:28 Reinstallation
9:38 Bleeding the slave cylinder
10:23 Thanks!
Why did I do this?
In the weeks before the repair I noticed some clear-ish fluid pooling under the front sprocket cover when the bike was parked. And the last time I rode the bike before the repair, it was difficult to shift. This evidence led me to conclude that the fluid was DOT4 from the hydraulic clutch system and that the clutch release cylinder seal had failed.
Thank you to to the following KZreadrs who have inspired me to tackle bigger motorcycle repair jobs and to create instructional videos of my own:
Moonfleet41: / @moonfleet41
Moto Mirius: / @motomirius
Mustie1: / @mustie1

Пікірлер: 21

  • @Moonfleet41
    @Moonfleet415 жыл бұрын

    What a wonderful video, almost like an online service manual, lots of clear images and great narrative... you could follow this easily and get the job done.. congratulations on your channel and getting underway... we wish you many happy videos to come!

  • @JDnBeastlet

    @JDnBeastlet

    5 жыл бұрын

    Thank you for the kind words, my friend. Your channel has helped me in immeasurable ways.

  • @Grunchy005
    @Grunchy00527 күн бұрын

    Screw sizes: everything is M6 including the two #3 Phillips bolts inside. Those are M6x10mm long, I was able to replace them with M6x12 no problem. M6 screws use the 5mm allen key. The two screws that hold the cylinder to the case are M6x25mm long. The other screws are: M6x55 (top of case), M6x40, M6x45 (left & right side of shifter), M6x75 X3 (left side of slave cylinder, underneath slave cylinder, and right side of case). (The two bolts at top & right side of case I'm not sure of because my sprocket cover got destructed due to the chain breaking on the road & bashing out the top of the cover, so I'm actually missing those two bolts.)

  • @wilfrex5019
    @wilfrex50194 жыл бұрын

    amazing video, im rebuilding an 98 1200 and I wasn't sure how to deal with the clutch release, I thought I had parts missing now I know everything is there.

  • @JDnBeastlet

    @JDnBeastlet

    4 жыл бұрын

    I glad you found it helpful. Good luck with the project!

  • @MariuszZaleski13
    @MariuszZaleski133 жыл бұрын

    Thanks for the video. I found out there is two diameters of the seal. 37mm and 40mm. They look quite similar. I bought 40mm for GSF1200 Bandit 01-05 and it doesn't fit to MK1 1200 from 1996. I couldn't figure how you managed to fit it so easily and I couldn't. I guess a thing to be aware of when looking for seal replacement.

  • @JDnBeastlet

    @JDnBeastlet

    3 жыл бұрын

    That's really good to know... Thanks!

  • @hoomanpictures
    @hoomanpictures3 жыл бұрын

    Hi, great video, I had the same problem even after replacement of the rubber seal, the problem was that i installed the rubber with the slot outside, the same as in your picture, the slot has to be in the inner spring side. best regard from Hamburg

  • @JDnBeastlet

    @JDnBeastlet

    3 жыл бұрын

    Thanks for the information!

  • @MrDN81

    @MrDN81

    3 жыл бұрын

    I was wondering about that too, if you put the seal in like in the picture, the fluid can go past it and it will leak again. The open side of the seal should be facing the bottom of the bore, right?

  • @hoomanpictures

    @hoomanpictures

    3 жыл бұрын

    @@MrDN81 exactly, this is really important. best regards

  • @rossi675446
    @rossi6754462 жыл бұрын

    Such a great and informative video 2 things where can I get a manual like that for my 2007 1200s bandit and where did you buy the mityvac from please

  • @JDnBeastlet

    @JDnBeastlet

    2 жыл бұрын

    Peter, thanks for the kind words. The manual is a Clymer covering the Bandit 1200 from 1996 to 2003, and very well written in my opinion. It came with the bike so I don't know the source; I would suggest checking with your local motorcycle shops and online. I think I got the Mityvac at my local UAP/NAPA auto parts store, but I see amazon has it as well.

  • @banditrider613
    @banditrider6132 жыл бұрын

    what manual are you using as it looks very good ,

  • @JDnBeastlet

    @JDnBeastlet

    2 жыл бұрын

    I have a digital version of the factory manual and a Clymer, which is where the images are from. I've had lots of Haynes manuals before and I find the Clymer to be a step up.

  • @volymard
    @volymard Жыл бұрын

    I am really struggling getting the clutch back up on mine. The master cylinder has pressure and new seals. The slave doesn't seem to have any effect on the clutch at all, the piston doesn't come back in, but keeps accepting pressure until the piston seal just gives. Can't see whether it's exerting any pressure on the push rod. Doesn't seem to be. &#$@ these crappy little hydraulic clutches, they suck

  • @JDnBeastlet

    @JDnBeastlet

    Жыл бұрын

    Hey Matt, sorry to hear you're having trouble. Is there any chance that you have the slave cylinder piston seal installed backwards?

  • @volymard

    @volymard

    Жыл бұрын

    Hey thanks for your time, It's a second hand slave so it may just be worn? I will sure check that, It's been doing my head in a while now, lol I hear the liner on the hose can sometimes obstruct, but it seems clear. I put new seals in the master cylinder that's good as. The metal retainer on the piston is a bit rooted. But it should be stopped, by the clutch pushrod and it's not going back into the cylinder when the clutch is released, instead it keeps on coming until it pops. I have had the clutch housing in bits, but I've checked it three times it's in the right order Ah well keep plugging away try a slave cylinder rebuild I guess

  • @kubconpl
    @kubconpl3 жыл бұрын

    will this fit in to bandit 600 mk1?

  • @JDnBeastlet

    @JDnBeastlet

    3 жыл бұрын

    I have no way of knowing, but don't the 600s have a cable actuated clutch?

  • @kubconpl

    @kubconpl

    3 жыл бұрын

    @@JDnBeastlet 600 have cable but im thinking to change

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