Jusy wondering if you've tried anything else. Been awhile. Mine is still the same. Lever play increases briefly, but only after accelerating.
When I have time I'm thinking I'll try rebuilding the slave cylinder. Not too expensive to try it. Maybe the rod isn't greased as it should be with that molybdenum grease or maybe the piston is somehow sticking. Just shooting in the dark but seems possible. Seems you and I have the same problem and you were thinking it might be the master cylinder. Could be I suppose but I don't know how acceleration could effect the MC?
Any help appreciated. Love the bike but this clutch thing has put a serious ding in our relationship.

Maybe the rod isn't greased as it should be with that molybdenum grease

..was my first thought. Just a guess. It would be easy to oil it with whatever motor oil you use and see if that helps it.

Thing is, the pushrod goes right into the crankcase. Should be all kinds of motor oil sloshing around in there to lube the pushrod. I think the molly DS is just a treatment to put a molecular film of slippery platelets on there. It is like tiny slippery shingles. Graphite is the same but does not stick as well.

If you are not getting oil onto the pushrod for some reason, that may be the prob. I would pull the rod and oil it up by hand. See if that makes any difference at all. Very pure Molly coat is about $60 for a small tube. Good to have on hand but kinda pricey if it does not solve the issue -- I don't think lacking the special coating would matter if oil was getting to the pushrod as it should.

KAK,

Did you mean me?

I got the master cyl kit but have not yet done the rebuild. Most of my issue was solved by getting the stack height a tad thicker. Had some warped steels and some pretty thin fibers in there as well. I did order all new steels and fibers but have not yet used them as I had enough spare parts to work it out good enough to make a few more passes. So the only problem I have left is the lever doesn't seem to return 100% when let out slow sometimes, and not every time. I think that is what we discussed in a previous thread? Gonna be next spring before I'll be able to give you a full report. I got it good enough to finish the race season then tore it apart for two other projects. (nitrous and relocating the air ports on my swing arm integrated air tank.) I have another MC to ride in the meantime. Besides, there are not many good riding days left in my area this year. I can ride cold and wet but I don't enjoy it at all so I don't do it anymore. ;)

Get the master cylinder kit and slave kit and tell me if it fixes it.

* Last updated by: motoCycho on 10/31/2011 @ 2:56 AM *

Moto, sorry I got your username wrong.
Still trying to figure out the problem. Haven't had time to work on it, just think about it.
In a thread I made awhile back it sounded like you had the same problem but I'm not so sure the way you describe it now. My problem is the amount of "play" in the lever changes. My lever returns quickly. There's no issue with the MC piston/rod assembly sticking. If a lever doesn't return quickly, as you say yours doesn't, then my experience says a rebuild of the MC and good cleaning will fix that. It assumes all air is removed of course.
I don't know what to think about my problem. I'll try a new thread and give the best detail I can and maybe someone can help or at least explain what the various parts do and maybe that can help me make a good guess as to what to replace.