Dead clutch?

[socwkbiker]

This one may get confusing, so hopefully I can explain it well and answer any questions.

Yesterday I got to ride for the first time this year. I changed the oil, ran the engine a while, checked fluid levels, etc. I got out on the highway and suddenly the bike started jerking and bucking. Rev up and shoot forward then out of gear and coast, then shoot forward again and coast. I rolled on the throttle, heard the engine rev but kept slowing down because I didn't seem to be in gear. I revved the engine, fluttered the clutch repeatedly, would go into gear for a couple of seconds then out again with the engine dying.

I pulled over when the engine cut out and got it to start after the bike seemed to recycle all power. I thought I might have some bad gas, so I filled up with premium and took off.

Got down the road a short while, very short, and the same stuff started happening. When I finally got to my destination, after noticing that to go into gear I had to slowly let the clutch out, I had to stop at a light. When I put the bike in first, released the clutch, slowly rolled a foot or two and nothing. The bike wasn't in gear. I got off the road and did notice that it slightly rolled on its own, but then nothing again. After that, i put the bike in first and nothing happened at all. The bike wouldn't go into gear, but the engine did run normally, so I'm thinking the engine is fine, but the clutch is shot.

Folks, I'm looking for a lot of help here. I've got one opinion input on this. from a friend here, but want to get more

[ringadingh]

I'm not sure I fully understand the problem, it sounds like there are possibly two separate issues. The clutch failing shouldn't have anything to do with the motor stalling and cutting out.
You may have had some bad fuel causing the motor to act up. And perhaps the clutch needs a new spring or slave cylinder, is the fluid ok? Did you check it? Can you put the bike in gear with the motor shut off and does it roll, or is it locked in gear like it should be.

[socwkbiker]

Originally Posted by ringadingh

I'm not sure I fully understand the problem, it sounds like there are possibly two separate issues. The clutch failing shouldn't have anything to do with the motor stalling and cutting out.
You may have had some bad fuel causing the motor to act up. And perhaps the clutch needs a new spring or slave cylinder, is the fluid ok? Did you check it? Can you put the bike in gear with the motor shut off and does it roll, or is it locked in gear like it should be.

The fluid level is ok and it's locked in gear like it should be in first.

[ringadingh]

So it won't release, and let the bike roll when the clutch lever is pulled in. Is that correct?
The gear shifter works ok doesn't it, or is it jammed in gear?

[socwkbiker]

Originally Posted by ringadingh

So it won't release, and let the bike roll when the clutch lever is pulled in. Is that correct?
The gear shifter works ok doesn't it, or is it jammed in gear?

Correct. It's difficult to get the gear into first. It sort of has to be jammed.

[ringadingh]

You should be able to gently rock the bike in gear with the motor off, and it should click into the gears without a whole lot of trouble.
If you can't do this you may have a bent shifter fork, or something wrong in the shifter drum.

If the clutch isn't releasing, it could be the slave cylinder, did the seal pop out on you?

[socwkbiker]

Originally Posted by ringadingh

You should be able to gently rock the bike in gear with the motor off, and it should click into the gears without a whole lot of trouble.
If you can't do this you may have a bent shifter fork, or something wrong in the shifter drum.

If the clutch isn't releasing, it could be the slave cylinder, did the seal pop out on you?

I had to replace the seal last year. That was a hassle because the original seal went in rather than out like most. The bike did click into gear, btw.

[cnc]

I think Steve is right 2 separate issues going on here. If your bike has been siting in storage in an unheated environment and a less than full tank, you probably have water in the gas from condensation.

I'm not sure I understand the clutch problem. Is it that the clutch is not properly engaging when you let out the clutch lever, or you are having a hard time getting the shifter to shift and lock into gear.

[AlabamaNomadRider]

I'm with Norm on the gas situation. Possibly has some water in it. Did the gas sit in the bike for an extended period?

Possibly the clutch plates might be sticking after sitting. Just a thought from an old mind.

[MAS Tequila]

Change the clutch fluid and check to be sure the slave cylinder is releasing properly.

You say you changed the oil, are you positive you didn't put oil in that has some type of friction modifier?

My first thought is still clutch fluid. If it is contaminated it could easily cause these symptoms.

MT

[socwkbiker]

The bike did sit for an extended period without a full tank. I did put some seafoam in, but I don't think enough. What can be done about that problem?

The bike would come out of gear completely and I couldn't get it to go back re-engage until I downshifted from 5th to 4th, and that didn't always work either. I did smell something like it was burning just as I got to my destination. As of now though, the bike will go into gear, but doesn't move. If you want clarification, call me in the evening 469-939-9497. I told you this wasn't easy.

Now, what's the process to changing the clutch fluid? Never had to do that.

[cnc]

In the garage section you can download to pdf file the shop manual.
The procedure for the clutch fluid change is described on p 57. More involved clutch info is available on page 270.

With regard to the fuel, you could dump in a bottle of isypropl gas line antifreeze to absorb the water, and run it out. It may take a tank or two to totally get rid of the moisture in the gas and depending on the amount of it the engine may buck and kick from time to time till it is all gone. Or, you could drain and flush the tank with a bit of fresh gas, then refill with fresh gas and isypropl or seafoam for good measure.

[ringadingh]

Originally Posted by socwkbiker

I had to replace the seal last year. That was a hassle because the original seal went in rather than out like most. The bike did click into gear, btw.

Perhaps the seal popped out a second time. I'd change the brake fluid in the clutch regardless just to rule it out.

[cactusjack]

Originally Posted by socwkbiker

I had to replace the seal last year. That was a hassle because the original seal went in rather than out like most. The bike did click into gear, btw.

I believe you're talking about the clutch pushrod seal, Jeff. That shouldn't have anything to do with the operation of the clutch. Its purpose is to prevent crankcase oil from leaking around the clutch pushrod shaft. If it's out of place, you make leak some oil, but the clutch would still work.

You said you changed the oil...what kind of oil did you use?

[blowndodge]

Guys I'm the "one" person he's talking about. I talked to him for about 30 minutes on the phone. Sounds like several issues. He started his bike for me and I told him to kick it into gear without using the clutch just to see if it killed the motor and stall. It didn't!!?? he said it moved a little bit but I could hear it was still running. It shouldn't be running. It should have stalled. Now unless he totally fragged his clutch completely it would still stall.

He stated that it was running normally but then told me he noticed slipping last year? The day in question it wasn't slipping so bad he couldn't get the bike up to speed and then after popping out of gear several times it would move forward in first at all... I'm say it isn't the clutch. Remember he had his transmission repaired under warranty a while back.