Master cylinder or slave? 2001 barn find

[TexasRich]

Been working on the Nomad that I picked up Sunday. Going well enough in figuring out what the problems are.

I have some questions about the clutch system. It is non existent at the present. I drained the old and replaced with new. Can’t seem to get it bled.
I pulled the master cylinder and cleaned it out. As far as I can tell, all air is removed from system using vaccum pump.

So, I ordered a master cylinder rebuild kit as well as a slave cylinder kit.

Any thoughts or suggestions as to what the problem may be? I see no evidence of leakage. Lever has some pressure to it and will push fluid through when bleeding manually. But the clutch will not even try to engage.

Thoughts?

[Rasta]

Is the bike running? Are you going down the road ?

[TexasRich]

No, but getting there. I have a slave rebuild kit that I’m going to install tomorrow. If that doesn’t work, I’m going to look closer at the master cylinder - maybe rebuild again to see if I missed something.

I’m convinced it’s in the hydraulic system tho, not the clutch itself. We’ll see tho. It’s killng me tho. Brakes are newly installed, fuel leak fixed and starts and idles perfectly. I’m dying to get it some road time.

[plumber63]

Maybe a bad hose. The old rubber could be bad and expands so doesn't put the pressure on the clutch it should.

[dhuttonkc]

Don't miss cleaning the tiny ass hole in the very bottom of the reservoir. It clogs easily and renders function non-existent. You will miss it if you are just using brake clean.

[TexasRich]

Actually, I think I figured out my problem - I’m an idiot. I realized that the master cylinders for the brake and clutch are NOT the same. Therefore, the kit for the brake mc (which I ordered) is not the same as the clutch. So nothing fit well and I always wondered why.

So, I ordered the clutch kit tonite. Should know next week. At least this isn’t the primary bike. So it’ll take as long as it takes. Ugh.

[mr500]

https://www.vulcanrider.se/en/kawasa...rvice-manuals/

[miltonsain]

it happens to all of us, brain farts happen more often, the older you get, lol

[TexasRich]

Well, new mc kit and new slave kit - same results. Still getting tiny stream of bubbles from slave when trying to bleed. Tried bleeding at the master cylinder as well, but no change. No difference if I pump the lever several times of not.

Any ideas?

[Monkeyman]

Have you replaced the hose as plumber suggested? If there's a pinhole in the hose, it might let in enough air to do that. It will work its way up to the highest point.

[waterman]

Originally Posted by TexasRich

Well, new mc kit and new slave kit - same results. Still getting tiny stream of bubbles from slave when trying to bleed. Tried bleeding at the master cylinder as well, but no change. No difference if I pump the lever several times of not.

Any ideas?

Are you bleeding the old fashioned way by pumping up the clutch and then breaking the bleeder valve? Try a suction system. I use a syringe and small hose. Crack the bleeder valve and suck with the syringe.

[TexasRich]

New hose on way. Going to keep trying using some of the suggestions offered. Thanks much guys.

[TexasRich]

Update: I replace the clutch hose today. Same result.

I stopped into the Kawasaki dealer near where I was working this week. He suggested that I open the oil cap, position the clutch basket where I can see the discs through the oil filler hole. Then simply engage the clutch and see if anything moves. I did, and it did move. I did the same in my 99 Nomad, results were the same. He said that it is common on a bike that has sat, for the clutch to lock in. So he suggested that I use a screwdriver and gently tap between the discs to see if this will unfreeze the unit, if that’s the problem. So I did, and the result is the same. But it does point to the problem being on the clutch side, not hydraulic.

So if it’s not the clutch locked up, could it be the spring? Any suggestions? Or am I going to need to tear into the clutch housing next?

[TexasRich]

Problem solved and the new Nomad took its first ride after resurrection today! The clutch had seized due to sitting. I followed the Kawasaki techs direction and gently pried the two plates I could see through the oil filler opening. I did this with the clutch lever clamped down. Then I warmed the bike to operating temp, poured some oil in slowly over the clutch basket. I left it over night with the lever clamped.

Went out today, started in neutral, warmed up, and dropped into first. The clutch was breaking free. Rode around neighborhood in first slowly. Worked in and out of first and neutral. Then started shifting into second. On to third and up to fifth. Filled tank, went on proper ride and voila! It’s fixed!

On to the little details while I put some miles on it! Thanks for the help gang!

[MrMikey]

good for you, glad you got her fixed up.................Mike