[Dr. Acula]

?....

I'm doing the dance with this problem also. I'm 90% certain it's in the master cylinder. I honed mine yesterday. It was good in my garage, then dragging at the first stop light. I turned to head home and in the parking lot it was normal.Pulling in the garage, dragging. Does anyone know an alternative ( cheaper ) clutch master assembly? A factory one is is near $200.

[shpielers]

Not sure about a cheaper one, but what did you use to hone it? I haven't seen anything that small.

[Dr. Acula]

Grainger had a 14mm bunch of grapes type. It wasn't cheap, but worked perfectly. Unfortunately, it didn't solve my problem.

[retcol]

I rebuilt both the clutch master cylinder and the clutch slave, added a braided clutch line, replaced the fluid, bled the crap out of the system and the clutch still drags.

[Dr. Acula]

I had done all that during a major refresh in 2012. Back then it worked perfectly. I'm hoping one of the Kat Jedi know of an alternative master as a new oem is big $$$$ for a try part. But I'm feeling that it's a master the way its acting. Maybe that's the mistake we're all making. It may be a part that doesn't rebuild well.

[Wild-Bill]

Bleed that banjo bolt on the MC. I've tried all kinds of bleeding/reverse bleeding techniques but every one relies on cracking that stupid banjo bolt and getting the air out there.

[kdo58]

i bleed the clutch and now it works like it should. i bleed it like i did the front brakes i found a good right up on the gixxer forum.

http://www.gixxer.com/forums/showthread.php?t=283074

[buffalobill]

The tape on the bleeders is new to me, but I'd be careful when wrapping it, so it don't get into the fluid stream.
I use a vacuum pump sometimes, but yea air gets down the bleeder threads.