Clutch lever pull...hard


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twocams
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Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Clutch lever pull...hard

Postby twocams » Tue Feb 23, 2016 7:33 pm



Bike been sitting for 5 yrs. Bleed the clutch and brakes. But the lever pull seems to be way harder than my 84 I had back in 1996. i hear the clutch engage when pulling lever, not running. I have started and engaged the transmission without rear wheel on. Everything seems to work OK. There is no free travel at the lever, and some hydraulic clutches dont. Is this normal. Works smooth all the way to handle bar. But I think just one day on the road Im going to have corpiltunal in my wrist. Any thoughts out there?

Twocams



pixel288
Posts: 44
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Location: Brighton, Ontario
Motorcycle: 1985 GL1200 Aspencade
1982 GS400E Suzuki
2009 CBR 125R HRC colors (daughter's bike)
1982 GL1100 Interstate

Re: Clutch lever pull...hard

Postby pixel288 » Tue Feb 23, 2016 11:06 pm

I'd check to be sure the return port in the master is completely clear... If it is partially plugged this would account for a hard pull.
Phil

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twocams
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Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
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Re: Clutch lever pull...hard

Postby twocams » Tue Feb 23, 2016 11:53 pm

Thanks Phil,
Ill look at that in a few days. Im still under Dr. orders. Dont do anything you dont have to, for a few more days.

Twocams

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WingAdmin
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Re: Clutch lever pull...hard

Postby WingAdmin » Wed Feb 24, 2016 12:16 pm

twocams wrote:Thanks Phil,
Ill look at that in a few days. Im still under Dr. orders. Dont do anything you dont have to, for a few more days.

Twocams


Crack open the clutch bleeder and squeeze the handle. If it's still hard to pull, then you've got an issue with the handle itself, or most likely the master cylinder.

If there is little to no effort to pull it when the bleeder is open, then either a) there is an issue with the slave cylinder, or b) you aren't as strong as you used to be. :)

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WingAdmin
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Re: Clutch lever pull...hard

Postby WingAdmin » Wed Feb 24, 2016 12:16 pm

Oh, and after sitting that long, you should be FLUSHING the brakes and clutch, not just bleeding - that could also be the source of your problem.

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twocams
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Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: Clutch lever pull...hard

Postby twocams » Wed Feb 24, 2016 1:01 pm

guess I should have said I bleed the brakes and clutch with new fluid. Also changed the engine oil/filter 2 times and hasn't even left my shop yet. :D I like the three clutch handle adjustments on my Beemer. Maybe thats the problem Ive been riding BMW to long. And ya I used to bench press #200 but cant even pull a clutch lever with ease. :x

Twocams

pixel288
Posts: 44
Joined: Tue Jul 15, 2014 11:29 pm
Location: Brighton, Ontario
Motorcycle: 1985 GL1200 Aspencade
1982 GS400E Suzuki
2009 CBR 125R HRC colors (daughter's bike)
1982 GL1100 Interstate

Re: Clutch lever pull...hard

Postby pixel288 » Wed Feb 24, 2016 7:23 pm

Hey TwoCams: here is a little light reading :lol: while you take it easy.... Rebuild/flushing the Clutch Master cylinder.... It's actually in the 1500 section, but it is apparently the same as our 1200's
Hope this helps

Phil

viewtopic.php?f=14&t=10988

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oldishwinger
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Re: Clutch lever pull...hard

Postby oldishwinger » Fri Feb 26, 2016 4:59 pm

its usualy the return port in the master cylinder, or the copper bush in the handle is out of round. my money would be on the return port. put a new kit in, and clear the port, by using a spray can of brake disc cleaner with a straw. it clears it and wont leave residue.

as the bike warms up. there can be tendency for the engagement to be at the end of the lever, but thats normal, it shoud be an easy pull through out.

good luck.

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twocams
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Re: Clutch lever pull...hard

Postby twocams » Fri Feb 26, 2016 7:38 pm

Maybe Ill get a master cylinder rebuild kit? Can't hurt, maybe even make the pull easier. :roll:
Thanks for yalls input.

Twocams

thompsoj22
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Re: Clutch lever pull...hard

Postby thompsoj22 » Sat Feb 27, 2016 7:31 am

just my opinion, but a clogged return port would allow momentary play at the handle on multiple successive pulls. as stated if you open the bleed on the slave and the lever pulls without resistance id lean towards the slave cyl being gummed/corroded and creating friction. Also as stated id remove the lever first and check the bushing as that is the simplest place to start. im new to these wings but do people install heavier clutch springs/diaphragm to pull trailers?

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twocams
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Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: Clutch lever pull...hard

Postby twocams » Sat Feb 27, 2016 12:42 pm

I took the clutch lever bolt loose last nite...with no play present. I ordered a master cylinder rebuild kit, cause like you say start on the easy first. May end up rebuilding the slave also, later. There was some corrosion and gunk inside the master when I flushed it a month ago.

Twocams

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Rednaxs60
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Re: Clutch lever pull...hard

Postby Rednaxs60 » Sat Feb 27, 2016 1:36 pm

twocams wrote:I took the clutch lever bolt loose last nite...with no play present. I ordered a master cylinder rebuild kit, cause like you say start on the easy first. May end up rebuilding the slave also, later. There was some corrosion and gunk inside the master when I flushed it a month ago.

Twocams


While you are doing this, I'd replace the lever bushing. After 31 years, it's bound to not fit as per new.

Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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twocams
Posts: 554
Joined: Tue Sep 29, 2015 11:25 am
Location: Grants Pass, Oregon
Motorcycle: 1985 GL1200 Aspencade, 2003 K1200GT BMW, 1969 R69S BMW
Sold : 84 V65 Magna, 82 Moto Guzzi, XS 1100 Yamaha,84 Wing Int., 80 650 Special, Only new bike 82 XV750 Virago (Guam),Honda 250,84 R100RT BMW,87 K100 LT BMW,93 K1100 LT BMW, 91 535 Virago, Honda 50

Re: Clutch lever pull...hard

Postby twocams » Sat Feb 27, 2016 1:59 pm

Come on now, I dont want to replace everything. It only has 30,000 miles on it and feels good. What's that saying they used on "Wild Hogs" movie......"I just wanna ride"!! :lol:

Twocams

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Rednaxs60
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Re: Clutch lever pull...hard

Postby Rednaxs60 » Sat Feb 27, 2016 2:09 pm

I hear you!! Every time I look at something, I find something else. I am my own worst enemy though.

If it wasn't for the exchange rate, would like to take a ride down through your area.

Ride safe, have fun!!

Cheers

8-)


"When you write the story of your life, don't let anyone else hold the pen"

Ernest


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