Clutch failure, twice; Dealer has no clue whats wrong

[MrMung]

My 2007 has about 38k on it, and was showing signs of clutch plates "sticking" to the point the bike would die when put into gear....also very hard shifting while moving. Took it into Desert Valley in Prosser, where I bought the bike, for clutch repair, and complete change of all fluids at same time. Brake, hub, fork, coolant and clutch fluids all changed. They also found worn clutch plates, so replaced them all with new OEM Yama parts. Expensive!

Rode the bike the 200 miles home, no problem, bike ran really well, till a week later.... Pulled in clutch lever to make a gear change, and the lever "collapsed" to the handgrip...no resistance at all. No shifting, nothing. Bike is now coasting to a stop, in permanent neutral. And the lever has gone from being completely loose, to rock hard, cant be moved. No leaks.

Desert Valley made the trip to retrieve the bike, and fix the problem! Very cool! They found a clutch part was installed backwards, so they corrected it and tested it out OK.

A week later, and the SAME THING HAPPENS AGAIN......stranded, clutch has gone limp, permanent neutral.

Called Desert Valley, and they came again to get the bike, very frustrated as well. Mike L. is not sure what could be going on.....nor do I.

Does anyone have ideas on what is going on? My suspicion is the hydraulic clutch system....not the clutch itself....

Any help is really appreciated!!

 

[BkerChuck]

Pure speculation on my part and may be completely off the mark.

I have a friend with an older Honda Goldwing tell me a story about a similar issue with the hydraulic clutch on his bike. Clutch hose had broken down internally with a small flap of the rubber hose broken inside. Flap would move like a valve allowing fluid motion in one direction and then sort of pop out, restricting return flow. They spent significant time tracing this and only found it when they removed the offending hose and blew low pressure air through it in both directions. Going one way it would work fine, other direction it would interfere. They also noted too much air pressure would overcome it and it wouldn't be noticed. Hard to diagnose and not something I've heard of often but could match the symptoms you describe.

Good luck and keep us posted.

 

[ionbeam]

* your dealer needs to call Yamaha

and/or

* you need a new dealer

Whether they are technically good or not, at least their customer service seems to be good.

 

[redjay]

I heard something about newer Gold Wings having similar issues. Turned out they were using the wrong brake fluid ?

 

[MrZappo]

At its heart, it is not a very complex system ... Your dealer seems nice and looks to be trying to stand behind their work but ...

I did my own clutch recently (as have many others) for similar symptoms and I got it back together correctly the first time .... As I said, It is not hard as long as you take your time and pay attention ...

The fact that they found a part installed "BACKWARDS !!?!?!?!??!" the first time is a major RED flag for me ... The dealers (try as they might) are forced to hire mechanics from the local community that are willing to work for peanuts ... This is not a good combination ...

I would have serious questions about what else is installed incorrectly ..

I would not trust them to make this right either ... Check with another dealer or better yet, find another FJR guy from this forum who has done a clutch or two and buy him a case of beer (to drink after he helps you) ...

As I said, these clutch mechanisms are not very complex. If it is totally failing in the way you have described, there is likely something serious AND obvious that is wrong ...

 

[gixxerjasen]

They should hire better mechanics. All my clutch parts were installed correctly by my mechanic.

 

[RadioHowie]

Desert Valley....ain't that where Warchild holds court?????

 

[DeSudet]

While you're at it, get a refund on all those Gen-yoo-whine Yama parts and spend some of it on a quick conversion...

https://www.barnettclutches.com/1314/yamaha/0/0/2013-yamaha-fjr1300.html

 

[JamesK]

While you're at it, get a refund on all those Gen-yoo-whine Yama parts and spend some of it on a quick conversion...
https://www.barnettclutches.com/1314/yamaha/0/0/2013-yamaha-fjr1300.html

Those Barnett clutch bits are nice, albeit expensive, however, the OEM clutch assembly works just fine too, oh and it lasts well too. My old engine died at 213,000 miles and I was still on the original clutch, which was never opened and it wasn't even slipping. I'm looking forward to examining it to see what it looks like when I strip down the old engine.

 

[C&C]

Sounds as they need to investigate the clutch slave and master cylinder. Best of luck with a fix; at least your dealer seems committed to getting this fixed.

 

[Fred W]

This is definitely a hydraulic issue. Because of the odd and intermittent symptoms, this could also be some sort of unusual problem in the ABS hydraulic valve block.

 

[RossKean]

ABS?? - Not in the clutch of MY '07.

 

[rickysnickers]

Sounds as they need to investigate the clutch slave and master cylinder. Best of luck with a fix; at least your dealer seems committed to getting this fixed.

I was thinking this as well.

 

[MrMung]

Thanks everyone for weighing in!!

I also am beginning to think this is a hydraulic issue...master/slave/system.... not sure....

And yes, this is the shop where Warchild frequents, Ignacio as well.... One of the reasons I purchased the bike there, and have it serviced there.....

They are likely opening the bike up this morning to see what they find. Think I will give em a call and point out the forum consensus, and see if they can find a problem in the hydraulic system....

Finally, I have to give Kudo's to Desert Valley....they are trying hard, and know I have been bringing the bike to them for the last seven years for service (other dealers near my place have screwed up even simple work). They have now made two trips across the Cascades to retrieve the bike, lets hope this is the last....

MrMung

 

[Nanahanman]

Sounds as they need to investigate the clutch slave and master cylinder.

This would be my suggestion as well.

 

[wfooshee]

Clutch lever will lock up if the slave cylinder is not mounted tightly, or if something in the mechanical link from slave piston to clutch is missing. Like that little ball at the end, or something like that. It has some spring pressure which makes it expand to the farthest extent that it can, and if it's not restrained it will extend to the limit of its travel, which "locks" the lever.

 

[wheatonFJR]

...

 

[JDavis07]

Hi,

I read but don't post much.

For what its worth my 07 ABS had an unacceptable clutch MUCH to stiff ---not news.

I replaced the slave cylinder with a brand new 06 part. A much easier pull but closer to the handelbar.

The slave seemed to have a slight 'catch' about halfway when it was installed new but I thought it just needed a

break in.

Periodically the clutch would drag and the clutch would not release fully. Useable but not releasing well.

Recently I removed the slave cylinder and cycled the slave with my thumb.

Seemed OK. I cycled it again and it extended farther than the first time.

I cycled it several times and it seemed smoother. and extended well.

After reinstalling the slave the bike shifted more smoothly. No other changes.

You might check the slave for smooth spring extension especially if it is an 06 part with less movement.

You can hear the clutch with the engine off. Quickly and barely actuate the clutch lever. It makes a faint tick or

click from the right side if operated sharply with little lever movement. [very faint sound at least on my 07]

oh yeah,

Yamaha claims in my shop manual that .011" movement causes full clutch release. That has GOT to be a misprint.

Surely it must be .110 .and that seems tight.

FYI

hope this helps!

 

[Constant Mesh]

2.8 mm (0.11 inches) or more of clutch pressure plate stroke is required for proper clutch operation according to the service manual.