Technical Bulletin 238
05.2024

Contents
Item

Subject

Model Affected

238.1

New Clutch Slave Cylinder

Tiger 1200 GT Pro, Tiger 1200 GT Explorer, Tiger 1200
Rally Pro, Tiger 1200 Rally Explorer

Technical Bulletin 238 Issue 1

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Item:

238.1

Description:

New Clutch Slave Cylinder

Model Affected:

Tiger 1200 GT Pro, Tiger 1200 GT Explorer, Tiger 1200 Rally Pro, Tiger 1200 Rally
Explorer

A new clutch slave cylinder and hose assembly has been introduced for the above models from VIN BV3121.
For models up to VIN BV3120, the original clutch slave cylinder and hose are no longer available. If replacing
the clutch slave cylinder is required, a parts kit is available. Refer to the Electronic Parts Catalog (EPC) for
further information regarding parts kit and replacements.
The procedure for installing the new clutch slave cylinder and hose assembly is described below.

WARNING
Make sure the motorcycle is stabilised and adequately supported.
Do not support the motorcycle on any ancillary component, the exhaust system or any other non
structural parts of the motorcycle frame.
A correctly supported motorcycle will help prevent it from falling.
Failure to follow the advice above could result in serious injury or death.

CAUTION
If the engine has recently been running, the exhaust components can be hot.
Always allow the hot components to cool before working on the exhaust system.
Contact with the hot components could cause minor to moderate burns to exposed skin.

NOTICE
To prevent paint damage, do not spill brake and clutch fluid onto any area of the bodywork.
Spilled brake and clutch fluid will damage paintwork.

Clutch Slave Cylinder Removal
Perform the following operations:
Remove the following components as described in the Service Manual:
• Seat
• Battery
• Fuel Tank
• Airbox
1.
Release the fixings and detach the clutch slave cylinder bracket from the clutch cover.

NOTICE
Note the position of the split line on the lifter arm to the alignment mark on the lifter shaft for installation.

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2.

Remove and discard the fixing on the lifter arm and slide the lifter arm from the splined lifter shaft.

5
4

2
1

3
B02121

1.
2.
3.
4.
5.

3.

Fixing
Lifter arm
Fixings
Bracket
Clutch slave cylinder

Move the lifter arm in the position shown below and detach it from the clutch slave cylinder by sliding
out the retaining pin.

1
2
3

cljj

1.
2.
3.

4.
5.

Clutch slave cylinder
Retaining pin
Lifter arm

Remove the dust cap from the bleed screw on the slave cylinder.
Attach a transparent plastic tube to the bleed screw.

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6.

Place the other end of the tube in a suitable receptacle containing new brake fluid. Keep the tube end
below the level of fluid.

3

2

4

1

IASM00058

1.
2.
3.
4.

7.
8.

Bleed nipple dust cap
Bleed screw
Bleed tube
Container

Counter hold the clutch hose union bolt and open the bleed screw.
Slowly pull in and release the clutch lever several times to drain the brake and clutch fluid.

NOTICE
Note the orientation of the clutch hose for installation.
9.
10.

Remove the dust gaiter.
Turn the slave cylinder adjuster until free from the bracket and remove the slave cylinder.

2

1
B02095

1.
2.

Spring detent plate
Clutch slave cylinder

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11.

Disconnect the clutch hose from the master cylinder and discard the two sealing washers.

3

2
1

B02090

1.
2.
3.

12.
13.

Union bolt
Sealing washers
Clutch hose

Cover the head of the clutch hose to prevent any remaining fluid leakage.
Remove the cable guides on the left and right hand side of the headstock. Discard the fixings.

1

2
3
clhr

1.
2.
3.

Cable guide (right hand side shown)
Fixing
Clutch hose

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14.

Detach the front and lower ends of the rubber covers from the left and right hand electrical connector
housings (right hand side shown).

1
2

3
IASM00106

1.
2.
3.

15.

Rubber cover (radiator assembly removed for clarity)
Front retaining lug
Lower retaining lug

Remove the clutch hose by routing the hose out of the motorcycle frame. Note the routing for
installation.

2
3

1
clid

1.
2.
3.

Frame
Clutch hose
Brake hose

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16.

Release the clutch hose from its retaining clips to route it out.

1

3
2

clif

1.
2.
3.

17.

Retaining clips
Clutch hose
Throttle body

Remove the clutch slave cylinder and hose assembly from the motorcycle.

Clutch Slave Cylinder Installation
1.

Fit the components of the new clutch slave cylinder in the order shown below.

1
6

2
3
4

7

5