All, I recently lost all pressure on my clutch master cylinder, so my bike jumped forward when I changed into first gear. Luckily, I had the brake pulled:-) Anyway, after trying multiple bleeds and refills, I finally gave in and located a Brembo 98.5029.70 rebuild kit that contains all of the parts needed for the typical rebuild. I was able to partially remove the clutch cylinder from the handle bar (i'm not the most mechanically inclined person) and then proceeded to remove the old pieces, the spring, bolt o-ring, etc. While I was careful to remove everything without breaking it, I did use pliers to remove some of the parts. Unfortunately, I am now unable to figure out in what exact order the rebuild kit pieces go back in to the master cylinder. I printed out the old manual and workshop manual, BUT the info is not pictured clearly enough and it is also showing a piece not part of the actual master cylinder nor the rebuild kit. Specifically, I have all the new parts to replace the old parts but cant figure out in what order and how tog et them in there. It seems there is one crucial piece of order related to the larger rubber piece and some type of metal crush washer? I can provide pics as needed, but I really need help getting this sorted today or tomorrow. I need to ride the bike out of a storage building and back to my house. Everything else works:-( Thanks for any assistance.

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this shows the Ducati #000047226 repair kit and the order it`s installed (looks a little different compared to what the manuals show)

Thanks for all the feedback, it allowed me to complete the rebuild with the Brembo kit without any problems. Unfortunately, it did NOT resolve by problem. After install and filling up with fresh fluid and bleeding appropriately and building proper pressure, the bike still jumped when I shifted into first gear, showing that the clutch was still not engaging when pulled. I'm out of ideas, what could be the issue here, it's not at the master cylinder or clutch lever. Please help!

Hi Martin.

Only thing left is the slave cylinder. Rebuilt kit available from your friendly neighborhood Ducati dealer or replace the whole lot with an aftermarket unit.

Cheers
Nick.

I'm thinking of something different.
You said you need to get the bike out of the storage building so I take it the problem did occur after a longer storage and not during a ride.
Remove the clutch cover, pull and release the clutch to see if the clutch discs move freely or if they stick together.
You could remove all clutch discs and clean them with sandpaper.

If that isn't it I'd check the slave cylinder next but if that was not ok it would probably leak, wouldn't it?

if the clutch discs or some of them stick together the clutch won`t disengage. Have to admit that 4 month is not really a long time for that to happen. Still worth checking.

PS: late afternoon in the US, early morning in Australia, after midnight here. I'm off. Good luck!



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1986 Vespa T5 125

Hi Martin,

You haven't mentioned when your clutch was last checked/overhauled, or for that matter where your clutch lever used to engage gear drive and how it engaged prior to storage?

Several things spring to mind... I would check the clutch basket for notch wear, along with clutch pack stack height, and clutch pack layout.

In terms of the basket look for notching along the edge where the clutch plates make contact/drive. If excessively worn it could be hanging up the plates from moving smoothly.

If the basket is fine then check the clutch pack stack height, plate condition, and check placement of the spring plates within your clutch stack. In particular the spring plates placement within the stack can make quite a difference in terms of snatch. I have seen several different spring plate placement configurations in that regard.

Cheers,

Marc

When you have checked the clutch and didn't find a problem remove the slave cylinder. I would expect it to be dry (other than maybe some grease there should be no brake fluid). What you can try is to hold the cylinder in one hand pressing the thumb firmly on the piston while carefully pulling the clutch lever. You should feel pressure building up againt your thumb. You can let the piston move out a few millimeters. Do not take your thumb off the piston before you let the lever go! (or it will pop out)
If there is no or little pressure or you can feel it decrease there could be air in the system or one of the clutch cylinders could be faulty. If the slave cylinder leaks while you do the test it's clear. If it doesn't the problem must be in the master cylinder (although you just rebuilt it).

When you dis-/reassembled the clutch master cylinder did you turn the lever adjustment screw? If you did you may have changed the lever stroke and it could be too short. (that screw should be left alone unless it's really necessary to make a change)

sounds like the slave cylinder , mine was blown and leaking fluid when it failed... but i had the same issues , no pressure on the clutch lever , and it wouldnt shift at all.. and jump hard when i put it into 1st gear

how did this story end?