QuestionI have a 2002 1400 Intruder that has developed clutch hydraulic problems at approx 5100 miles on the odometer. I was stuck in backed-up traffic the other day on a hot day when the clutch hydraulics started to fade away. I immediately got off the interstate and, once, the bike started moving and cooled off some, most of the hydraulics came back. A motorcyle dealer mechanic told me the problem was burned brake fluid in the clutch system.
I bought new DOT4 fluid, bled system per the shop manual with the vacuum pump on the transmission end of the tube. I've gotten all the black, burned fluid out and now only have clear fluid coming through but I cannot get the system to re-pressurize.
1st attempt to repair - ordered clutch master cylinder kit - rebuilt MC when kit came in. No scoring or other evident damage to cylinder bore. Replaced both washers for bolt that fastens clutch hydraulic line to master cylinder. Tried to bleed system both with and without vacuum pump. No joy. I get very little fluid out of the bleed nipple after pumping and holding clutch lever.
If I have MC cover off while pumping clutch lever, I get air bubbles out of forward reservoir hole, sometimes out of rear hole, and frequently get brake fluid squirting up into the air.
I am at wits end - never had a system that would not bleed before. I assumem there is an air plug somewhere in system, but even vacuum pump on bottom won't take it out.
Any suggestions?
AnswerHi Roger,
If rebuild kit is properly installed, then what you're experiencing happens once in a while.
Send me an email address as requested. I'll return some files on the subject matter that may help you.
mshively1@woh.rr.com
Respectfully,
Mark Shively
