Motorcycle Repair: Clutch Problems, hydraulic clutches, intruder 800

Question
I have a 98 intruder 800. The gears were clunking when I shidfted gear so I had the clutch plates replaced, Still clunking so I bought a kit for the hand lever and put in a new master cylinder. TO the best of my knowledge system is bled correctly. With the side panel off clutch only moves about 1/4 inch when clutch depressed. It still clucnks, Any ideas?




(http://


Answer
Hi Gordon.
 The problem that the Intruders have is identical to what a number of bikes with hydraulic clutches have.

 Some bikes have an additional problem with both the clutch and front brakes, including my own.  The problem stems from the configuration of the master cylinder, which is that the connection to the hydraulic line at the master cylinder creates a pocket that air bubbles like to hide in (this is called a reverse trap) and the method for bleeding that section is a little tricky if you've never done this before.

 Here's the proceedure;

1) Bleed the clutch/brake line like normal.

2) Put a wrench on the banjo fitting and squeeze the lever.


3) (NOTE: Use a box end wrench for this) While holding the clutch/brake lever in, crack loose the fitting and reclose it quickly. Have a rag over the fitting connection that you are working on because it will spit at you as pressure expells the air and a little fluid.

***************IMPORTANT NOTE: Do not release pressure on the lever till the fitting is tightened back up or you will suck air back into the line.

4) Test the clutch/brake again.  If done correctly, you will have pressure near the beginning of the lever movement rather than at the end.

5) repeat as needed, but should not need more than 2-3 times.

Good luck.
FALCON