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Discussion Starter · #1 ·
Hi guys,

Need some feedback... Working on a friends 1999 1500 and when I picked it up I noticed a very late engagement of the clutch - that is to say, the lever is almost all the way out before the clutch engages...

Didn't notice and slipping or chatter, just a very late engagement... I'm thinking I might try to bleed the clutch and see if that helps... Other things I am thinking - maybe the actuator rod is worn in the slave unit, or perhaps the clutch itself???

The clutch was not on my list of to-do's for my friend on this bike, but it bother's me that the engagement is so late...

Any thoughts or ideas ideas??? Bike has just over 50K on the clock but maintenance generally has been lacking...

Les
 

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Discussion Starter · #5 ·
I'll look at the bushing Dennis - thanks... Levers are OEM so no issue there... My friends are not the type to hold me responsible for a clutch going out - they are really nice people and asked me to do some maintenance because they are not mechanically inclined... Actually, I'm working on "her bike" now, his bike will be later in the week...

I owned a 1993 Aspy for 20 years so I know how the clutch should feel, and something isn't right on this one... Just looking for possible fixes guys short of replacing the clutch which I will not do as I don't have the proper tools for that job...
 

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Discussion Starter · #12 ·
OK Stu and others - thanks for all the tips... I didn't work on it today as the kids were over for a BBQ but I'll start again on it tomorrow... Have to pull the rear wheel tomorrow and replace a badly scored rear rotor... Then I'll replace the rear pads and bleed the systems including clutch...

I'll report back on what I find... I've never worked on a slave cylinder before - this could be a new experience for me - good thing I kept my 1500 shop manual ;)

Les
 

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Discussion Starter · #14 ·
Bleed the clutch today (many times) and it's still the same... Also disassembled clutch lever and checked and lubed master cylinder plunger and associated components - no change...

Pulling slave unit tomorrow morning to see what I can see - hopefully it will be an epiphany tomorrow and I'll find out what's wrong... I may try to bleed the clutch assembly at the master cylinder banjo bolt tomorrow as I have a little help coming over in the morning and see if that makes any difference... The master cylinder is quite a bit higher than the clutch at that point so that would be a good spot for an air bubble...

Les
 

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Discussion Starter · #16 ·
In the continuing saga of the late engaging clutch - today I pulled the slave cylinder and inspected it and cleaned it... There was a little junk in there but not bad at all... Refilled and bled the master cylinder again and same thing - still late engagement...

Tried bleeding the clutch at the banjo fitting on the master cylinder thinking there might be an air bubble trapped high - no dice - same issue...

Let me reiterate here that I owned a 1500 (my 93 Aspy) for over 20 years and my clutch was never this low... I am stumped and have told my friend that to the best of my knowledge, either a new clutch is needed or there is something going on I am not aware of... I have officially "punted" on this issue... It's not in my make-up to give up on a problem but this one truly has me baffled and I have run out of ideas to try...

Ken - yes, it is an issue of late engagement of the clutch - the clutch lever is almost all the way released before the clutch engages... My friends hands are not that small and I don't believe I am chasing ghosts... I owned and operated my 1500 for over 20 years, and did all my own wrenching on it and as mentioned earlier, this clutch action is not normal for a 1500, and in fact, this was confirmed by my buddy today as he test rode the bike too and confirmed the late engagement of the clutch... He was also a 1500 owner (actually he had 2) for many years...

At this point the only guess I have left is clutch replacement - I cannot find anything else wrong with this clutch assembly...

Les
 

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Discussion Starter · #19 ·
Well, that's a good idea Stu... Yeah, both these bikes (the other comes in today) are from my very good riding friends in the MC club... They are great people and we really enjoy their company both on and off the bikes but alas, neither are technically inclined and unfortunately, they have little time or motivation for maintenance, so I try to help where I can...

I agree - 50K is very low mileage for needing a clutch and one would really have to work at destroying it for that to happen... The particular bike in question with the clutch issue goes back to the owner today and another one comes in for service so I doubt that I will be continuing with the clutch issue further unless it becomes drastically worse...

Thanks for all the replies and suggestions - wish I could have solved the problem - I would have felt better about it if I had...

Les
 
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