Jumps and stalls when put in gear

[sprtsmn]

Went to take the bike out for the first time this year. Checked the oil and the air in the tires. Bike started like normal and I let it warm up a bit. As soon as I put it gear the bike jumped and stalled. Pulled the clutch to put back into neutral and would not come out of gear. Had to roll it back and forth to slip it back into neutral. When I tried to start it while in gear and the clutch engaged it jumped forward like the clutch wasn’t engaged. I figured because it try to start with the clutch pulled that rolled that the clutch switch operated properly and the stand switch operated properly. I found the clutch reservoir empty so I filled it and bled it. Same thing happened. Could it be the slave cylinder has failed completely? I forgot to mention that it is a 1991 1500 Intersate.

[bellboy40]

I think I would take a look at the slave cylinder and see if you see any signs of brake fluid around there. That fluid had to go somewhere. It would probably be a good idea to take it off and clean it up anyway and replace the seals in it.

[sprtsmn]

I didn’t see any signs of an external leak. I am assuming it went into the crankcase. So I will be changing the oil and filter after I take care of the clutch issue. Thank you for the response. I just wanted to bounce it off somebody before I spend money on parts I might not need.

[DenverWinger]

The clutch plates may simply be "stuck together", this can happen if the bike has been just sitting a while.

If you are sure you have all the air bled out of the hydraulics and the clutch lever feels "normal" but the clutch still won't disengage, here's how to free "stuck" clutch plates:

With bike on center stand, start engine, put bike in 1st gear and run the revs up to around 3000 RPM. Rear wheel will be spinning. Pull the clutch lever in all the way, then stomp on the rear brake and hit the gas both at the same time. This will break your stuck clutch plates free and return the clutch to normal operations.

[bellboy40]

Yes it is possible, maybe even likely, the clutch plates are stuck. But he still needs to find where the fluid is going and fix that.

[sprtsmn]

My one big concern was that my clutch cylinder was empty. I had no external leaks and the bike was fine before I stored it for winter. Now it has been a very long winter for us so it is very possible that they are stuck. Thank you for the advise. I haven’t done anything to the bike yet so I will look into that.

[WingAdmin]

More likely that there is air in the line, and the clutch is not being completely disengaged because of it. And the air is there because it was sucked in after the reservoir was drained. So fix the problem causing the drained reservoir, refill and bleed the clutch system, and I would bet the problem is fixed.

But absolutely clean and perhaps flush the crankcase.

[sprtsmn]

Thank you for all the advise. It was the slave cylinder. It was pretty much blown out. I changed the oil. Put a new cylinder on and bled it. Hopefully going to get out this weekend for a ride. Weather pending. It is Michigan.

[Bettynbillinga]

I have an 84 1200 standard. My problem started with a leaking sight glass in the clutch master cylinder. After fixing the leak I refilled with DOT 4 and checked to see if the clutch would disengage the rear tire with the clutch in. It did not. I bled the system at the master cylinder banjo bolt, slave cylinder banjo bolt and bleeder valve on the slave cylinder housing. I put the bike in gear with the engine off and depressed the clutch and it would not disengage the rear wheel. I tried the process described above by putting the bike in gear starting and rev to 3000 rpm and jammed the brake with the clutch in and no success. I did this several times and it still will not disengage. Could it possibly be the slave cylinder? I am new to this forum and appreciate any help I can get.

[Happytrails]

I'm not familiar with the 1200's but sounds like its possible. The 1500's have a piston and rubber seal(s) so if the piston isn't pushing the pushrod to the clutch when you pull the lever the clutch wouldn't disengage. There isn't much to them and they aren't hard to service (on a 1500). You could try taking yours apart and rebuilding it. There has to be replacement parts available I'd hope.

[Bettynbillinga]

Thank you for the rapid response. I have ordered speed blenders to give it one more try at bleeding before going into the slave cylinder.i understand that trying to bleed the 1200 clutch can be a real challenge.

[Happytrails]

Anytime, hope it goes well. I looked but didn't see any guides although people saying its similar to rebuilding the slave cylinder on a 1500 so thats good. I'm sure someone who has/had a 1200 will chime in and be more help than me. But I did find this blog that somebody did rebuilding there 1200 slave and it does look very similar to a 1500. And it looks like the parts are readily available. Good luck!

http://goldwingrebody.blogspot.com/2013 ... build.html

[Bettynbillinga]

Well the story continues. I received the speed bleeders and ran a quart of DOT4 through the slave cylinder and no change. I removed the slave cylinder with the clutch line still connected and activated the clutch and the piston moves out but easily goes back in. I thought the piston may have been stuck so I put it back together and no difference. I removed the slave cylinder again and removed the piston and spring and there was significant corrosion so I guess my next step is to get the cylinder kit. It shows available at Cheap Cycle Parts for $102.00.

[Happytrails]

Sounds like progress. You might want to compare prices to Partzilla. Both really good although Partzilla sometimes has better pricing.

[Bettynbillinga]

The Honda shop in my town gets their parts from Partzilla which is just across town. I don't have to pay shipping. I appreciate the response.

[Bettynbillinga]

And the story continues. I received the speed bleeders, ran a bottle of DOT4 through the slave cylinder and still no clutch. I ordered and installed a new slave cylinder, ran another quart of DOT4 through the slave cylinder and still no clutch...... I removed the slave cylinder again and just lightly depressed the clutch and the piston comes out and will not depress with the clutch lever depressed but will retract with the clutch lever released. I tried starting the engine, put it in gear, revved the engine to 3000 pulled in the clutch in hit the rear brake and applied the throttle and still no help. Did this several times but gave up for fear of damaging something. Any help is greatly appreciated.