Quick fix for "sloppy" clutch handle


Information and questions on GL1200 Goldwings (1984-1987)
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zamboni920
Posts: 250
Joined: Sun Aug 14, 2011 5:15 am
Location: Stavanger, Norway
Motorcycle: 1996 GL1500 SE with Hannigan 2+2 sidecar

Quick fix for "sloppy" clutch handle

Postby zamboni920 » Sun Jun 24, 2012 8:31 am



I had the problem of my clutch not disengaging completely when shifting into gear from neutral. This seemed to only happen when cold.....when putting into gear first time before riding. I assumed it was the clutch components in the engine case beeing worn, and I still think there is a problem there. However, I found the brass bushing in the clutch handle beeing extremely worn, and didn't push the master cylinder piston plunger far enough in. So I manufacured a new one. Now it is a lot better....rear tire does not leave rubber behind when firt putting into gear anymore :P .
I had a similar bushing in my miscellaneous bin, exact same diameter. Just drilled a hole for plunger, a little less depth than original, giving it a bit more firmness. Also shaved off some of the large head on new bushing....original did not have a head at all. See attached pics.....if you experience similar problem, maybe you can make your own bushing also. I do assume the fact this bushing was made from brass, a soft metal, is because you'd rather wear the bushing than the hole in the handle itself.
Attachments
Original bushing and plunger
Original bushing and plunger
New homemade bushing
New homemade bushing
Installed, clutch pulled in
Installed, clutch pulled in



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virgilmobile
Posts: 7663
Joined: Sun Sep 19, 2010 5:39 pm
Location: Denham Springs,La.
Motorcycle: 1988 GL1500 I
Previously owned
78 GL1000
81 GL1100
82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: Quick fix for "sloppy" clutch handle

Postby virgilmobile » Sun Jun 24, 2012 1:06 pm

I like. :) :) :)
Great design and good engineering.

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goldwinger1
Posts: 19
Joined: Mon Mar 22, 2010 11:51 pm
Location: Winston-salem,NC
Motorcycle: 2002 GL-1800

Re: Quick fix for "sloppy" clutch handle

Postby goldwinger1 » Tue Jul 03, 2012 1:39 am

The next time the bushiung wears out , most Honda Dealers have that bushing in stock.
Buzzsaw

User avatar
zamboni920
Posts: 250
Joined: Sun Aug 14, 2011 5:15 am
Location: Stavanger, Norway
Motorcycle: 1996 GL1500 SE with Hannigan 2+2 sidecar

Re: Quick fix for "sloppy" clutch handle

Postby zamboni920 » Tue Jul 03, 2012 5:20 pm

Goldwinger....thanks, I should pick one up. This was a "bored Saturday afternoon" kind of job, so I used what I could find.
Virgil.....thanks for compliment.




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