Leaking master cylinder / clutch lever
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  1. #1
    Junior Member Rookie
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    Leaking master cylinder / clutch lever

    I own a 2009 525XC with less than 100 hours on it. All stock. I bought it about 4 years ago out of Georgia and at the time at had about 70 hours on it. Anyway, ever since I have owned it the master cylinder at the clutch lever has always leaked. After a few years of having to fill it up in order to ride (I go about 6 months or so before each ride because I don't live where it is stored) I bought reputable rebuild kit. Even after this rebuild the darn thing still leaks the same amount.

    I'm thinking its just a poorly designed seal. There is a little plastic disk that holds the seals in place and that thing is not only hard to get in and out, but it doesn't appear to do a very good job to me. I was thinking I read somewhere that one is better to use an updated master cylinder setup that KTM eventually moved to on their motorcycles in later years.

    Can any one direct me what I should do here? If there is a better update KTM came out with I would be fine purchasing it and getting rid of the one I have.

    Thank
    M

  2. #2
    Senior Member KTMATVHQ Guru
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    I've had to rebuild my factory master cylinder on my XC a few times. Never had to rebuild the one on my SX quad. I finally ended up picking up a used SX master and put it on my XC. The clutch pull is slightly stiffer, but I like the SX lever better.
    Mine:
    2017 Husky FX 450
    2009 505 SX
    2008 525 XC-modded for mx (currently 450 cylinder)
    Dad's:
    2009 450 SX
    2008 540 XC

  3. #3
    Junior Member Rookie
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    Great feedback. Thanks.

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  5. #4
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    Quote Originally Posted by quad97 View Post
    I've had to rebuild my factory master cylinder on my XC a few times. Never had to rebuild the one on my SX quad. I finally ended up picking up a used SX master and put it on my XC. The clutch pull is slightly stiffer, but I like the SX lever better.
    I looked yesterday and the part number for the 505SX and 525XC are the same - 77302030000. I sort of wonder if they didn't standardize around and the best one in recent years? I had heard a while back that the original master cylinder used on the XC had problems and that later revisions that were used on the SX and Motorcycles proved to be much better. Not sure but I'm going to try a new one to see if that fixes the problem. The clutch has never worked at 100% since I got the XC a few years back and I think its because air was getting in the system.

  6. #5
    Senior Member KTMATVHQ Guru
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    According to the Rocky Mountain parts diagram the 2008 XC master cylinder has been superseded from 83002030000 to 83002030100 and has a 9.5mm piston. The 2009 SX master (same part number you specified) is a 10.5mm piston so that's why it feels a little stiffer. The 2009 XC master shows the same part number as the SX. Not sure why they are bothering to have the different superseded one for the 2008 model.
    Mine:
    2017 Husky FX 450
    2009 505 SX
    2008 525 XC-modded for mx (currently 450 cylinder)
    Dad's:
    2009 450 SX
    2008 540 XC

  7. #6
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    Quote Originally Posted by quad97 View Post
    According to the Rocky Mountain parts diagram the 2008 XC master cylinder has been superseded from 83002030000 to 83002030100 and has a 9.5mm piston. The 2009 SX master (same part number you specified) is a 10.5mm piston so that's why it feels a little stiffer. The 2009 XC master shows the same part number as the SX. Not sure why they are bothering to have the different superseded one for the 2008 model.
    Just so I follow. You are saying the 2008 XC changes from 3800203000 to 83002030100. However, the 2009 xc parts diagram calls for 77302030000. Right? I'm thinking the right part for either year is the 10.5mm one. Not necessarily due to the capacity increase, but I think they learned of some weaknesses in the 9.5MM design that they changed in the 10.5mm design. I have seen on numerous boards where folks suggest changing out the original XC 9.5mm cylinder with the one of the dirt bikes or SX model which are all 10.5mm.

    Thanks!


 

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