Clutch Woes

[Ozark]

I know some of you can help me with this. Clutch started acting up on a ride Saturday. When I left town all was well, but as time went on, the play in the clutch lever steadily increased. It got to the point that it would disengage about 1/4" from the handgrip. Fearing it would get worse I returned home and topped off the reservoir. This morning while is was cool it seemed a little better. On the way home after work, I had almost no release left. I actually needed to blip the throttle to help it shift up or down. It's not slipping at all, just not releasing soon enough for comfort.

Could it be air has gotten into the line somehow. It hasn't been dropped, but it was completely service recently. I would have expected any problems from the servicing to show up immediately though.

All help is needed and appreciated.

Jim

[muffinman]

Jim it sounds like the rubber line may be swelling with the heat it is a comon problem on our scoots normally I would say to flush the line with new fluid and that should take care of it but with a recent service I would say that the line is the problem.

Jeff

[Ozark]

Thanks for the input Jeff. I didn't have them replace all the fluids. I don't know how hard it is to change out the lines, but it sounds like bleeding them first just to check might not be a bad idea. What do you think?

By the way, just wanted to say thank you for all the help you've offered me and others on this site.

[Squidley]

Jim,

I agree with Muffin, my '99 did the sme thing last year on the way to Vogel and I swapped out the fluid down there and it solved the problem

[Redneck]

I would try flushing the system with fresh fluid first. If the fluid has absorbed enough moisture it will cause the symptoms you are describing. the moisture will boil when the scoot gets warm and cause air bubbles to form.

[Ozark]

If you three guys agree, it must be the way to go. Sounds like a good plan for tomorrow night and ride some on Wednesday to verify the fix. I do appreciate all the help. :happy34:

Might not make Fort Collins, but should see some of you at Vogel or E.S. Looking forward to riding together again.

Jim

[86er]

I have to agree with the others on this one, Jim. The only thing that I would add is to use the Valvoline Synthetic brake fluid (it's compatible w/Dot 3). I've swapped all my hydraulics to it and really like it.

 

If you ask real nice, Squidley has a picture of the bottle it comes in that he might post. (I'm too lazy to run downstairs with my camera, plus Sharon Stone is about to kill Gene Hackman!)

 

[muffinman]

Jim if you have to replace the line get a middle gear cover gasket you will need it.

Also use dot3 fluid not dot4 my local Yamaha shop said they have seen problems with the dot4 in some of the scoots around here.

 

Jeff

[Squidley]

Jim,

This is what I use for all the brake fluid needs on all my bikes.

Todd....you must have been watching the "The Quick and The Dead"

[bongobobny]

If you end up replacing lines, you may want to consider going the extra step and rebuild your slave cylander as well. Keep in mind how old the rubber is...

 

I'm presently in the middle of the same job myself. Not exceptionally difficult to do but getting the slave out requires a little coaxing. Right now I'm waiting on my new line to be delivered hopefully Friday.

[mbrood]

If you are wondering where that fluid went... you probably are in need of a seal kit for the slave. It's not a hard overhaul... just a minor pita.

[GeorgeS]

You probably need a rebuild kit in the Master, and Replace the Slave cylinder.

 

I opened my Master, at 50K on my 89, and the parts looked pretty Sad. even though it was still working.

 

The Slave cyl. had corrosion on the inner surface. I insatlled a rebuild kit, but if I had to do it over, I would just Replace the Slave cylinder, ( about $30 ) ( rebuild kit about $15 )

[Ozark]

Got up early this morning and started bleeding the hydraulic clutch. Man that old stuff was really nasty looking. Probably took me

1 1/2 hrs to get all the old fluid and air bubbles out but got it done. Took it for a ride and everything went well until we stopped to eat. My bike got a new sickness and belched the radiator dry. I was lucky that the place had a garden hose I could use. Drove it home and it didn't run hot, but still left a nice little puddle of antifreeze on the ground. What give guys, thermostat perhaps.

Again, thanks for all the help.

Jim

[GeorgeS]

Is it leaking from the Weep hole under the water pump?

 

If so, you will probably have to rebuild the pump.

 

Also, check the Overflow Lines at the top of the Small Overflow plastic tank, located in the Right hand Fairing.

 

If leak is from up front of the engine , could be one of many hoses, or the radiator, or the Cover Cap on thermostate. ( cover is PVC plastic, if sombody overtorqued the two bolts, it might have been deformed ) I had this problem, I overtorqued it, had to get a new one.

 

Also, there is a small line from bottom center of radiator, which is Only Press Fit into place. This is a fairly common leak point on 1st Gens. ( you can do a temp repair on this point with J/B Weld )

[Ozark]

It was too hot to get close to the first time. I'll investigate more fully now that I have it at home.

Thank you,

Jim