Another clutch question

**Kawalski Rider** · 07-08-2020, 05:25 PM

Greetings all.. I'm looking for a second opinion.
Recently took a 3500 mile trip on my always trusty 02 Nomad fi. Started out without issues. As the trip wore on I noticed shifting into neutral was getting more difficult. Readjusted the clutch lever to position 1, seemed to resolve it. The last 2 days of the trip about 800 miles, The problem resurfaced, getting harder and harder to get into neutral the more I rode it. I managed to make it home. After making it home, I noticed the clutch would not completely disengage. I rebuild the master and slave cylinders for the clutch system and flushed the hydraulics. The master was clean and all the ports seemed clear. The slave had some brown residue in it, which easily wiped out. After getting it all back together, the problem still exists. I put a 2/32" shim between the adjuster knob and the clutch lever and I can at least get it to shift into gear without stalling engine. But, getting it back into neutral is not easy. I'm reluctant to force it, I've seen enough dialog on this forum about that. The bike has 64,000 miles on it. I replaced the clutch friction plates about 30,000 ago, but did not replace the clutch spring, it's still the original. The clutch doesn't seem to be slipping, quite the opposite.

I'm wondering if the clutch spring may have warped or collapsed, causing the loose of through in the clutch, so it won't disengage fully.

All educated information and suggestions, would be gladly accepted

BrokeAss · 07-09-2020, 12:13 AM

You rebuilt both cylinders, but did you replace the line?

**Kawalski Rider** · 07-09-2020, 12:20 AM

Quote:

Originally Posted by BrokeAss

You rebuilt both cylinders, but did you replace the line?

No, I did not replace the line.

duo1983 · 08-30-2020, 12:18 AM

your issue sounds familiar, mine is currently having an issue like this as well at 50,000 I cant shift it out of 2nd gear anymore. so what line are you referring to?

DragonLady58 · 08-30-2020, 12:53 AM

Sounds like theres still some air in the line or in the system, or your hoses needs replacing. With a 3500 trip done, and it was good the biggest majority of the time, something has moved, leaked or otherwise shifted the clearances....

Jllm02199 · 09-03-2020, 01:54 PM

Sounds like the clutch isn’t disengaging.
I was having that issue many years ago. I replaced the rubber lines with steel braided.
No problem since. Keep clutch reservoir clean.

07-08-2020, 05:25 PM	#1
Kawalski Rider Join Date: Sep 2016 Location: Auburn, Washington Posts: 305	Another clutch question Greetings all.. I'm looking for a second opinion. Recently took a 3500 mile trip on my always trusty 02 Nomad fi. Started out without issues. As the trip wore on I noticed shifting into neutral was getting more difficult. Readjusted the clutch lever to position 1, seemed to resolve it. The last 2 days of the trip about 800 miles, The problem resurfaced, getting harder and harder to get into neutral the more I rode it. I managed to make it home. After making it home, I noticed the clutch would not completely disengage. I rebuild the master and slave cylinders for the clutch system and flushed the hydraulics. The master was clean and all the ports seemed clear. The slave had some brown residue in it, which easily wiped out. After getting it all back together, the problem still exists. I put a 2/32" shim between the adjuster knob and the clutch lever and I can at least get it to shift into gear without stalling engine. But, getting it back into neutral is not easy. I'm reluctant to force it, I've seen enough dialog on this forum about that. The bike has 64,000 miles on it. I replaced the clutch friction plates about 30,000 ago, but did not replace the clutch spring, it's still the original. The clutch doesn't seem to be slipping, quite the opposite. I'm wondering if the clutch spring may have warped or collapsed, causing the loose of through in the clutch, so it won't disengage fully. All educated information and suggestions, would be gladly accepted __________________ Cheers, David Baughan aka: Kawalski Rider VBA #03514 2002 Vulcan VN1500L Nomad fi Pearl Burnish Beige/Pearl Luster Beige Login or Register to Remove Ads
	0

07-09-2020, 12:13 AM	#2
BrokeAss Member Join Date: Sep 2018 Location: Ohio Posts: 297	You rebuilt both cylinders, but did you replace the line? __________________ '09 Nomad 1700 - Ivan's flash - Kuryakyn Alley Cat - V&H slip-ons - Triple hi/low beam H4 headlights - Desert Dawgs - Half the F&S Catalog
	0

08-30-2020, 12:53 AM	#5
DragonLady58 Sr. Member Join Date: Jul 2016 Location: Somewhere South of Alaska.... Posts: 2,359	Sounds like theres still some air in the line or in the system, or your hoses needs replacing. With a 3500 trip done, and it was good the biggest majority of the time, something has moved, leaked or otherwise shifted the clearances.... __________________ --------------------- Don't start no schit, there won't be no schit.... My Sarcasm is directly proportional to the amount of Stupidity involved --------------------- VBA#03239 VROC#37400 VRA --------------------- 2014 Vaquero 2001 Nomad FI 2003 Street Glide (sold) 1500 Meanie, fresh rebuild (sold) 90s BUBF Bobber (sold) 2001 UltraCycle FatPounder (Sold) 1975 HD ElectraGlide (Sold) 1982 Kawasaki Z1 Chopper (Sold) Suck It Up & Ride! Login or Register to Remove Ads Last edited by DragonLady58; 08-30-2020 at 12:58 AM.
	0

09-03-2020, 01:54 PM	#6
Jllm02199 Advanced Member Join Date: Aug 2012 Location: Morrow, Ga. Posts: 830	Sounds like the clutch isn’t disengaging. I was having that issue many years ago. I replaced the rubber lines with steel braided. No problem since. Keep clutch reservoir clean. __________________ 02 1500 Nomad (07 1600 Motor) 160,000 Red & Black 12" mini apes Galfer lines (6' over) EJK Dobeck Reckless Fairing. Led H4 headlight All LED lights Rockford Fosgate radio
	0

08-30-2020, 12:18 AM	#4
duo1983 Member Join Date: Jan 2017 Location: Fresno, CA Posts: 52	your issue sounds familiar, mine is currently having an issue like this as well at 50,000 I cant shift it out of 2nd gear anymore. so what line are you referring to?
	0