Motorcycle Repair: Clutch adjustment, banjo bolt, clutch adjustment

Question
Chris,

  I ride a '99 suzuki intruder 1400, I recently moved cross country.  I had my bike moved on a van, and ever scince the cluth seems to not fully engage.  The bike wants to continue to move forward even when holding the clutch.  Which I believe is the reason it is not allowing me to switch gears.  Two questions can this be fixed by a clutch cable adjustment?  And if so, how on this particular bike do I go about trying to do this?  Any knowledge you could share would be greatly appreciated.  Thanks.  -John  

Answer
Hi John.

The intruder does not have a clutch cable.  It is a hydraulic clutch.

 There are a few possibilities here;

1) There is an air bubble in the clutch line.  Bleed the clutch. a) Bleed the clutch like normal (just like the brakes). b) Then, with a cloth over the banjo fitting at the master cylinder and the tank (to protect the paint), then put a box end wrench on the banjo bolt and apply the clutch.  c) Without releasing the clutch, crack loose the banjo fitting and retighten it.  Then (and only then) release the clutch. d) Test the clutch and see if it feels normal.  Repeat as needed, but not more than 3 times.  If this does not restore normal operation, then there is another problem.

2) The clutch line is getting ready to burst.  If you see an unusual bulge in the rubber portion of the line, then replace the line.  Go to a shop that does brakeline rebuilds and get it redone in braided stainless.

3) The clutch has chosen this time to require a rebuild of either the master (upper) or slave (lower) cylinder.

Start with those and see what you find.

Good luck and ride safe.
FALCON