Motorcycle Repair: hydraulic clutch on 1982 honda magnam, clutch master cylinder, banjo bolt


Question
chris,
your alsome at this, i bought a 82 mag and has no manual with it, i was about to order one .need to know witch name brand is the best, and went to ride the other day no clutch, i do see fluild on floor,  one other thing,  be going strong down the road and then it loses power big time,  and a mile or to  it picks back up then loses again looking for all help thank you , the guy just had carbs rebuilt , is all i know of thanks again

Answer
Hi Garland.

 First thing, when you rebuilt the carbs, were they properly synchronized?  Was the valve gap and timing as well as the ignition timing done?  Tune-ups are critical when a bike is over 20 years old.

 The clutch is another problem altogether.  You may need a rebuild kit for the master and/or slave units (depending on where you are seeing the fluid leak).  These are not hard to replace and an average mechanically inclined rider can change both in under an hour.

 If you are not getting immediate pressure on the clutch after the leak is repaired, then what you may need to do is to bleed the clutch.  This is done in a manner identical to bleeding the front brakes.  In addition to that, the line has a naturally occuring reverse trap in it at the banjo bolt at the master cylinder.  here's the proceedure for bleeding the clutch master cylinder reverse trap;

Check the entire system for potential leaks and make sure that all connections are tight and within specs.  then proceed with the following proceedures:

1) Bleed the clutch as you would the brake.  Make sure that all of the air
bubbles that you can normally find are out of the system.

2) Check the clutch fluid level and top off as needed.

3) Cover the front area of the bike, near the handlebars on the clutch side, with rags. (you will see when you actually perform this whole proceedure)

4) With safety glasses on, place a wrench on the banjo fitting (the bolt that holds the clutch line to the master cylinder) and with the clutch depressed, break the seal on the fitting and (BEFORE releasing the clutch) tighten it back up.

5) Check the fluid level and test the clutch.

6) Repeat steps 4 and 5 up to, but not more than, 3 times or until the clutch works normally.

If this does not correct the problem, then there is the possibility that the slave cylinder needs to be rebuilt.  That requires a kit that should run you between 20-40 dollars.

 The average mechanically inclined individual can do the rebuild in about 20-30 minutes with common hand tools.

Let me know how it goes.

Good luck and ride safe.
FALCON