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Discussion Starter · #1 ·
So I got my bike home tonight and I know that there is an issue with the clutch. I took off the cover and the plastic topper. The rubber gasket underneath seemed all swollen and misshapen. It was too big to fit the master properly. Is this normal? The fluid in the master is see through with a slight yellow tinge to it. I will try to bleed it, but I want to know if all will be wasted if that gasket is messed up.
 

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1985 GL1200 A
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Yep, it's toast. Refresh the whole system once right and you won't have to think about it for quite awhile.
 

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Junior Grue
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The diaphragm opens like a bellows to follow the fluid as it leaks out and usually can be manipulated back to it's original shape.
If it's truly fubared a new one is only about $15.00 at your local dealer.

And yes it can be a PITA to get the cap on over the diaphragm.
 

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Discussion Starter · #5 ·
So the fact that the top of the gasket is bigger than the master is okay? I squished it all back in and got the plastic cover and cap back on. If the gasket is good I will bleed it and go. I seem to remember the brake gasket on my old CB550 was a similar setup.
 

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Just Winging It
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:?Where did the clutch brake fluid (DOT 4) go?:?

Most of the time that diaphragm just needs pressed back into shape like Ken said. I'd run a lot of brake fluid through the system if the diaphragm truly is misshapen due to contact with some caustic chemical.
 

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Junior Grue
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So the fact that the top of the gasket is bigger than the master is okay?
Nope, the diaphragm should fit into the recess on the top of the reservoir. Once the plastic plate and cap are on you should not see it.
 

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Discussion Starter · #8 ·
The Master was not empty at all. Still had fluid about a 1/4 inch up. When I squeezed the lever a could see a pulse of fluid from the smaller hole. The gent I bought it from said he pulled the lever and had tension and it just slowly "leaked down" and then no clutch reponse.
 

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Discussion Starter · #9 ·
I got it all inside and can't see anything after the platic cap and metal cap are screwed in place. Screws went in no problem and no binding. Should be good?
 

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Junior Grue
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Well the cap goes on which is good but now you have to finger out why it leaks down.
It could be a leaking slave cylinder or a leaking master cylinder.
 

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Vintage Rider
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One place to check for a leak is the sight glass in the master cylinder. Mine had a lot of hairline cracks in it to begin with. It looked like a smashed car windshield, and it leaked. Then the plastic (despite being called a site GLASS, it is actually plastic) just crumbled altogether and fell out.
 

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Discussion Starter · #12 ·
Got it fixed? One of my coworkers picked up my diaphragm for me since the closest dealer is a hundred klicks away. Got my plate and insurance tonight and started in. I did the turn the bars and flip the lever. This seemed to work a bit. I broke the banjo loose and did the same thing and I cold see air percolating by. Tightened the banjo and automatically got lever. Pressed it a few more times while the bubbles poured out. Waited for no bubbles and now I got a clutch. I will do a flush later, I just wanted to get it fixed. Took it out for a ride about town and what a nice feeling that is. Thanks for the help.
 

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killer driller
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781 Posts
:?Where did the clutch brake fluid (DOT 4) go?:?

Most of the time that diaphragm just needs pressed back into shape like Ken said. I'd run a lot of brake fluid through the system if the diaphragm truly is misshapen due to contact with some caustic chemical.
my 1200 has dot 3 only stamped on the lid, would it be better to use a dot 4 fluid
 

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Just Winging It
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I got the Dot 3/Dot 4 because it came in a larger bottle so I could flush my lines. Honda calls for dot 4 your cover must not be the original cover.:? PO mystery :?
 

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my 1200 has dot 3 only stamped on the lid, would it be better to use a dot 4 fluid
My 87 GL1200 says DOT 4. Maybe PO put a different lid on? I ended up not only flushing the system but rebuilt MC & SC. Pay attention to the smaller hole that has the metal shield thing stuck on top. Mine was plugged solid with some kind of aluminium corrosion and had to be cleaned out (I used welding tip cleaner wires). Otherwise, the fluid won't return to MC and eventually into the ride the clutch has built up pressure (you will have zero play at the lever when there should be a little) and the clutch will slip, badly. I have been through the clutch hydraulics from one end to another, brakes too.
 
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